Interpolymers suitable for multilayer films

ABSTRACT

The present invention relates to compositions and processes of making and using interpolymers having a controlled molecular weight distribution. Multilayer films and film layers derived from novel ethylene/α-olefin interpolymers are also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. application Ser. No. 11/762,643, filed on Jun. 13, 2007, now U.S. Pat. No. 8,153,243 which is aContinuation-In-Part Application of U.S. application Ser. No.11/608,171, filed on Dec. 7, 2006, which claims the benefit under 35U.S.C 119(e) of U.S. Provisional Application No. 60/749,308, filed Dec.9, 2005, both of which are herein incorporated by reference in theirentirety.

FIELD OF THE INVENTION

The present invention relates to ethylene/α-olefin interpolymercompositions having a controlled molecular weight distribution andmethods of making and using the compositions. More particularly, theinvention relates to using the ethylene/α-olefin interpolymercompositions in multilayer films.

BACKGROUND OF THE INVENTION

It is desirable to produce ethylene/α-olefin interpolymer compositionsof controlled molecular weight distribution in a cost-effective manner.In particular ethylene/α-olefin interpolymer compositions having amulti-modal (two or more modes wherein the case of two mayinterchangeably be referred to as bimodal or multi-modal) molecularweight distribution are often desirable for some applications, forexample, pipes for natural gas, sewers, mining, etc. Also, someapplications may require compositions wherein a low molecular weightportion of the ethylene/α-olefin interpolymer composition has a higherdensity than a high molecular weight portion of the ethylene/α-olefininterpolymer composition. Unfortunately, to date the available processesdo not effectively and efficiently control the distribution or result incompositions with the desired density and molecular weight combinations.Therefore, there is a need for processes that can control the molecularweight distribution or result in compositions with the desired densityand molecular weight combinations. There is also a need forinterpolymers having improved properties, e.g., heat seal and residualenthalpy, as well as, improved film layers and films having suchproperties.

SUMMARY OF THE INVENTION

New processes have been discovered which result in effective control ofmolecular weight distribution. Advantageously, the inventive processesmay be designed to result in compositions wherein a low molecular weightportion of the ethylene/α-olefin interpolymer composition has a higherdensity than a high molecular weight portion of the ethylene/α-olefininterpolymer composition. Also, the ethylene/α-olefin interpolymercomposition may be produced in a single polymerization reactor and/orusing a single catalyst. Novel compositions often may result from theaforementioned processes. The novel compositions comprise anethylene/α-olefin interpolymer composition with a multi-modal molecularweight distribution and one or more molecules having a gram molecularweight equal to about ((the molecular weight of an aryl orhydrocarbyl-ligand of a pre-catalyst)+28+14*X), wherein X represents aninteger from zero to 10, preferably zero to 8.

Novel multilayer films have been discovered that comprise:

-   -   (A) a base layer comprising a first polymer;    -   (B) a tie layer comprising a second polymer; and    -   (C) a sealant layer comprising an ethylene/α-olefin        interpolymer,        wherein the tie layer is between the base layer and the sealant        layer and wherein the ethylene/α-olefin interpolymer of the        sealant layer has a DSC curve characterized by an area under the        DSC curve from the melting peak temperature to the end of        melting is at least about 17% and, in most cases at most about        50%, of the total area under the DSC melting curve from −20° C.        to the end of melting. The interpolymer may have a B value of        greater than 0.98. Novel film layers have also been discovered        that comprise one or more novel ethylene/α-olefin interpolymers        having a DSC curve characterized by an area under the DSC curve        from the melting peak temperature to the end of melting is at        least about 17%, preferably at least 18%, of the total area        under the DSC melting curve from −20° C. to the end of melting.        Novel ethylene/α-olefin interpolymers have been discovered that        comprise the following characteristics: a density in g/cc, d,        and a weight percent α-olefin, Wt. %, wherein the numerical        values of d and Wt. % correspond to the relationship: d≦−0.0018        Wt. %+0.9297 and/or the relationship d≦−0.0019 Wt. %+0.933.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-14 are a series of slides explaining multi-site behavior incopolymerizations.

FIGS. 15-19 are differential scanning calorimetry (DSC) curves forpolymer made from Examples 4, 6, 12, 14 and 15, respectively.

FIG. 20 depicts molecular weight distributions of ethylene-octenecopolymers.

FIG. 21 depicts the effect of octene mole fraction on the fraction ofhigh molecular weight polymer.

FIGS. 22, 23, 24, and 25 show the DSC curves and melting peaktemperature obtained using a TA Instruments model Q1000 DSC forinterpolymers of Examples 16, 17, 20, and 21 respectively.

FIG. 26 shows the DSC curve and melting peak temperature obtained usinga TA Instruments model Q1000 DSC for polymer of Comparative Polymer A.

FIG. 27 shows a DSC curve and melting peak temperature obtained using aTA Instruments model 2920 DSC for polymer of Comparative Polymer A.

FIG. 28 shows the DSC curve obtained using a TA Instruments model Q1000DSC for interpolymer of Example 22.

FIG. 29 is a plot showing the density of an ethylene/α-olefininterpolymer as a function of the weight percentage of 1-octene forinventive polymers made using diethyl zinc (DEZ) and inventive polymersmade without using DEZ.

FIG. 30 is a graph showing the average hot tack force (N), i.e., averagehot tack strength, of the inventive multilayer films of BB and CC vs.comparative multilayer films of DD and EE.

FIG. 31 is a graph showing the average hot tack force (N), i.e., averagehot tack strength, of the inventive multilayer films of MM and NN vs.comparative multilayer films of OO and PP.

FIG. 32 is a graph showing a comparison of the average peak load andaverage total energy for an oriented film comprising the interpolymer ofExample 22 and an oriented film comprising Comparative Polymer G.

DETAILED DESCRIPTION OF THE INVENTION

General Definitions

If and when employed herein, the following terms shall have the givenmeaning for the purposes of this invention:

“Polymer” refers to a polymeric compound prepared by polymerizingmonomers, whether of the same or a different type. The generic term“polymer” embraces the terms “homopolymer,” “copolymer,” “terpolymer” aswell as “interpolymer.”

“Interpolymer” refers to a polymer prepared by the polymerization of atleast two different types of monomers. The generic term “interpolymer”includes the term “copolymer” (which is usually employed to refer to apolymer prepared from two different monomers) as well as the term“terpolymer” (which is usually employed to refer to a polymer preparedfrom three different types of monomers). It also encompasses polymersmade by polymerizing four or more types of monomers.

“Multi-block copolymer” or “multi-block interpolymer” refers to apolymer comprising two or more chemically distinct regions or segments(referred to as “blocks”) preferably joined in a linear manner, that is,a polymer comprising chemically differentiated units which are joinedend-to-end with respect to polymerized ethylenic functionality, ratherthan in pendent or grafted fashion. In a preferred embodiment, theblocks differ in the amount or type of comonomer incorporated therein,the density, the amount of crystallinity, the crystallite sizeattributable to a polymer of such composition, the type or degree oftacticity (isotactic or syndiotactic), regio-regularity orregio-irregularity, the amount of branching, including long chainbranching or hyper-branching, the homogeneity, or any other chemical orphysical property. The multi-block copolymers are characterized byunique distributions of polydispersity index (PDI or M_(w)/M_(n)), blocklength distribution, and/or block number distribution due to the uniqueprocess of making the copolymers. More specifically, when produced in acontinuous process, the multi-block polymers often possess PDI fromabout 1.7 to about 2.9, from about 1.8 to about 2.5, from about 1.8 toabout 2.2, or from about 1.8 to about 2.1.

“Density” is tested in accordance with ASTM D792.

“Melt Index (I₂)” is determined according to ASTM D1238 using a weightof 2.16 kg at 190° C. for polymers comprising ethylene as the majorcomponent in the polymer.

“Melt Flow Rate (MFR)” is determined for according to ASTM D1238 using aweight of 2.16 kg at 230° C. for polymers comprising propylene as themajor component in the polymer.

“Molecular weight distribution” or MWD is measured by conventional GPCper the procedure described by T. Williams and I. M. Ward, Journal ofPolymer Science, Polymer Letters Edition (1968), 6(9), 621-624, whereinCoefficient B is 1 and Coefficient A is 0.4316.

“Multilayer film” refers to a film having at least two layers.

“Tie layer” refers to an intermediate layer of a multilayer film whereinthe intermediate layer can promote the adhesion between two adjacentlayers of the intermediate layer.

“Sealant layer” refers to a layer of a multilayer film wherein the layercomprises a material capable of sealing. Typically, such sealing mayoccur upon exposure to, for example, heat. In some embodiments, thesealant layer is an outermost layer of the multilayer film.

“Base layer” refers to a substrate of a multilayer film wherein thesubstrate forms the base of the film.

A layer or multilayer film that is “substantially free” of an additiveor a compound refers to a layer or multilayer film containing less than20 wt. %, less than 10 wt. %, less than 5 wt. %, less than 4 wt. %, lessthan 3 wt. %, less than 2 wt. %, less than 1 wt. %, less than 0.5 wt. %,less than 0.1 wt. %, or less than 0.01 wt. % of the additive orcompound, based on the total weight of the layer or multilayer film.

In the following description, all numbers disclosed herein areapproximate values, regardless whether the word “about” or “approximate”is used in connection therewith. They may vary by 1 percent, 2 percent,5 percent, or, sometimes, 10 to 20 percent. Whenever a numerical rangewith a lower limit, R^(L), and an upper limit, R^(U), is disclosed, anynumber falling within the range is specifically disclosed. Inparticular, the following numbers within the range are specificallydisclosed: R=R^(L)+k*(R^(U)−R^(L)), wherein k is a variable ranging from1 percent to 100 percent with a 1 percent increment, i.e., k is 1percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . , 50 percent,51 percent, 52 percent, . . . , 95 percent, 96 percent, 97 percent, 98percent, 99 percent, or 100 percent. Moreover, any numerical rangedefined by two R numbers as defined in the above is also specificallydisclosed.

Controlling Molecular Weight and Density

It has been discovered that the molecular weight distribution of aresulting polymer may be controlled. For example, using the properreaction conditions (e.g., a well mixed homogeneous reactionenvironment, a steady-state concentration of two or more monomers suchas ethylene and an α-olefin like octene, and a proper pre-catalyst orcatalyst) the bimodal molecular weight “split” of the polymer may becontrolled by the mole fractions (f) of the two or more monomers, n,such that the mole fraction of monomer m is defined as:

$f_{m} = {\frac{\left\lbrack {Monomer}_{m} \right\rbrack}{\sum\limits_{i = 1}^{n}\left\lbrack {Monomer}_{i} \right\rbrack}.}$

That is, the molecular weight split can be controlled so that it isbasically a function of the relative monomer concentrations in solution.These same relative monomer concentrations also, depending upon thereaction conditions, may determine the overall composition (i.e.density) of the total polymer.

One aspect of controlling monomer purity useful herein is by utilizing aside stream of monomer in contact with a selected catalyst in a plugflow reactor. If the monomer is impure, then a lower than expectedexotherm will be observed in the plug flow reactor. In this manner,monomer purity is monitored and adjusted if necessary.

While not wishing to be bound by any theory the Applicants havediscovered that the reason that the monomer concentration:molecularweight split relationship can be made to occur is that a differentcatalyst species can be made from each monomer reactant. This means thata lower molecular weight polymer is formed by an “ethylene-inserted”form of the catalyst, while an “α-olefin-inserted” form of the catalystgives a higher molecular weight polymer. Advantageously, this results ina molecular weight split which is controlled by controlling the relativeamounts of the various catalyst species that are formed.

As an example it is believed that the Hafnium catalyst below can be madeto form an ethylene-inserted cation and an octene-inserted cation in thepresence of ethylene and octene and the proper reaction conditionsincluding, for example, a well mixed homogeneous reaction environment.

Therefore, the present invention allows one to control the molecularweight split in numerous ways. One method of the present inventioninvolves changing the ligand structure of a given catalyst to affect theresulting split for a given overall density copolymer. Thus, one mayselect suitable pre-catalyst(s) for the polymerization to control theconcentrations of an ethylene-inserted cation and/or an octene-insertedcation and thereby control the resulting molecular weight split.Alternatively, the present invention allows one to control the polymersplit from a given catalyst precursor. For example, one such methodwould be to do a pre-reaction or pre-polymerization of sorts, e.g.,contacting a pre-catalyst with a single monomer to generate the desiredcatalyst species concentrations, then feeding part or all of thispre-reaction product to the reactor. This could optionally be done withthe addition of pure pre-catalyst, providing a high degree of controlover the resulting polymer bimodality.

In yet another alternative of the present invention, the polymer splitcan be modified by changing process variables. For example, one cancontrol the amount of inserted catalyst by controlling compositiongradients—especially in instances when the insertion occurs in the earlystages of catalyst activation. In a solution loop reactor, for example,a gradient of monomer composition can be achieved by modifying the speedat which the reactor effluent circulates through the reactor. This canresult in differences in the comonomer mole fraction at different placeswithin the reactor. The reactor can be configured to take advantage ofthis by strategic placement of catalyst and monomer injection pointsand/or the timing of said catalyst and monomer contact.

In yet another alternative, one or more compounds can be synthesizeddirectly so that the desired ratio of ethylene-insertedcation:α-olefin-inserted cation can be directly controlled.

General Processes of Using a Pre-Catalyst to Control Molecular Weight

As stated above, the Applicants have discovered a number of ways tocontrol the molecular weight distribution in the production of anethylene/α-olefin interpolymer composition. One process comprises:

-   -   (a) selecting at least one suitable pre-catalyst comprising at        least one metal-aryl or metal-hydrocarbyl bond, wherein each        pre-catalyst molecule is essentially the same as every other        pre-catalyst molecule;    -   (b) contacting ethylene, at least one α-olefin, and said        suitable pre-catalyst;    -   (c) selecting ethylene:alpha-olefin concentration ratios        sufficient to activate the pre-catalyst, and    -   (d) forming an ethylene/α-olefin interpolymer composition under        continuous reaction polymerization conditions; and, optionally,    -   (e) selecting a molecular weight split of the interpolymer as        determined by the mole fractions (f) of the two or more        monomers, n, such that the mole fraction of monomer m is defined        as:

$f_{m} = {\frac{\left\lbrack {Monomer}_{m} \right\rbrack}{\sum\limits_{i = 1}^{n}\left\lbrack {Monomer}_{i} \right\rbrack}.}$to produce an ethylene/α-olefin interpolymer composition with acontrolled bimodal or multi-modal molecular weight distribution.

Another process comprises:

-   -   (a) selecting at least one suitable pre-catalyst comprising at        least one metal-aryl or metal-hydrocarbyl bond, wherein each        pre-catalyst molecule is essentially the same as every other        pre-catalyst molecule;    -   (b) contacting at least one organic compound, and said suitable        pre-catalyst;    -   (c) selecting at least one organic compound concentration        sufficient to activate the pre-catalyst, and    -   (d) forming an ethylene/α-olefin interpolymer composition under        continuous reaction polymerization conditions; and, optionally,    -   (e) selecting a molecular weight split of the interpolymer as        determined by the concentration of the one or more organic        compound(s) to produce an ethylene/α-olefin interpolymer        composition with a controlled bimodal or multi-modal molecular        weight distribution.        Suitable Pre-Catalyst Contact with (1) Ethylene and an α-Olefin        or (2) Organic Compound

The suitable pre-catalysts may be selected from any of those comprisingat least one metal-aryl or metal-hydrocarbyl bond. The aryl may be anymolecule or ligand which has the ring structure characteristic of, forexample, phenyl, naphalenyl, phenanthrenyl, anthracenyl, etc. Thehydrocarbyl may be any molecule or ligand comprising hydrogen and carbonsuch as benzyl. Additionally, a heteroatom such as nitrogen, oxygen,etc. may be substituted for one or more carbon atoms of the aryl orhydrocarbyl such that aryl includes heteroaryl and hydrocarbyl includesheterohydrocarbyl. Similarly, one or more hydrogens on the aryl orhydrocarbyl may be replaced with any substituent which does notsubstantially interfere with the desired activity of the pre-catalyst.Such substituents include, but are not limited to, substituted orunsubstituted alkyl, halo, nitro, amino, alkoxy, aryl, aliphatic,cycloaliphatic, hydroxy, and the like. Preferably each pre-catalystmolecule is essentially the same as every other pre-catalyst molecule.By this is meant that the chemical structures of the molecules aresubstantially the same. Also preferable are those structures in whichring strain is capable of being relieved from the metal-hydrocarbylligand when contacted with ethylene or an α-olefin.

Particularly suitable pre-catalysts are selected from the groupconsisting of hydrocarbylamine substituted heteroaryl compoundscorresponding to the formula:

wherein:

-   -   R¹¹ is selected from alkyl, cycloalkyl, heteroalkyl,        cycloheteroalkyl, aryl, and inertly substituted derivatives        thereof containing from 1 to 30 atoms not counting hydrogen or a        divalent derivative thereof;    -   T¹ is a divalent bridging group of from 1 to 41 atoms other than        hydrogen, preferably 1 to 20 atoms atoms other than hydrogen,        and most preferably a mono- or di-C₁₋₂₀ hydrocarbyl substituted        methylene or silane group; and    -   R¹² is a C₅₋₂₀ heteroaryl group containing Lewis base        functionality, especially a pyridin-2-yl- or substituted        pyridin-2-yl group or a divalent derivative thereof;    -   M¹ comprises hafnium or other Group 4 metal;    -   X¹ is an anionic, neutral or dianionic ligand group;    -   x′ is a number from 0 to 5 indicating the number of such X¹        groups; and        bonds, optional bonds and electron donative interactions are        represented by lines, dotted lines and arrows respectively, or a        mixture thereof, in contact with a suitable co-catalyst.

The pre-catalyst and optional catalysts if desired are contacted witheither (1) ethylene and an α-olefin or (2) an organic compound such as,for example, acetone or a mixture of ketones or (3) mixtures thereof, ina manner and in amounts sufficient to activate the pre-catalyst. Oneskilled in the art will recognize that a cocatalyst such as the onesdescribed below may be useful at this stage or a later stage. Theconditions will generally vary depending upon the polymer desired andthe equipment employed. However, one skilled in the art can readilydetermine the suitable conditions using the instant specification,background knowledge, the prior art, and routine experimentation.Guidance is given in, for example, U.S. Pat. Nos. 6,960,635; 6,946,535;6,943,215; 6,927,256; 6,919,407; and 6,906,160 which are incorporatedherein by reference. One advantage of the instant processes is that asingle catalyst may be employed in a single reactor.

The ethylene, α-olefin, and/or organic compound concentrations aretypically selected so as to be sufficient to activate the pre-catalyst,and form the desired ethylene/α-olefin interpolymer composition havingthe desired molecular weight distribution. These activation conditionsvary depending on the reactants and equipment employed and may be thesame but are preferably different than the continuous polymerizationreaction conditions used to form the interpolymer. More specifically,the initial monomer ratio used during activation may be the same but ispreferably different than the monomer ratio used during the interpolymerpolymerization. While these ratios often vary according the reactionconditions and the product desired, the molecular weight split of theinterpolymer may usually be controlled by selecting the mole fractions(f) of the two or more monomers, n, such that the mole fraction ofmonomer m is defined as:

$f_{m} = {\frac{\left\lbrack {Monomer}_{m} \right\rbrack}{\sum\limits_{i = 1}^{n}\left\lbrack {Monomer}_{i} \right\rbrack}.}$

Advantageously, the resulting polymer often has a low molecular weightportion that has a higher density than the high molecular weightportion. While batch or continuous polymerization reaction conditionsmay be employed, it is preferable to employ continuous polymerizationreaction conditions during the formation of the interpolymer. However,continuous polymerization reaction conditions can still be employed evenif the pre-catalyst is activated separately from the mainpolymerization.

General Processes of Using a Synthesized Catalyst to Control MolecularWeight Distribution

Another process of controlling molecular weight comprises contactingethylene, an α-olefin, and a suitable catalyst under reaction conditionssufficient to form an ethylene/α-olefin interpolymer composition whereinthe catalyst comprises a catalytic amount of a molecule having thestructure:

Wherein:

-   -   M=group 2-8 metal, preferably group 4 as a neutral or charged        moiety;    -   Y=any substituent including fused rings;    -   L=any ligating group, especially a pyridyl or pyridylamide;    -   X=alkyl, aryl, substituted alkyl, H or hydride, halide, or other        anionic moiety;    -   y=an integer from 0 to the complete valence of M;    -   R=alkyl, aryl, haloalkyl, haloaryl, hydrogen, etc;    -   x=1-6, especially 2;    -   Dashed line=optional bond, especially a weak bond; and    -   X and (CR₂)_(x) may be tethered or part of a ring.

Use of various forms of the aforementioned catalyst structure allows oneskilled in the art to directly control the concentrations of an“ethylene-inserted” form of the catalyst and an “α-olefin-inserted” formof the catalyst. By directly controlling these concentrations themolecular weight split of the interpolymer may be controlled. Thisallows one skilled in the art to employ a much wider range of reactionconditions yet still control the molecular weight distribution. Forexample, it is then possible to control the molecular weightdistribution over a wider range of monomer concentrations.

The above catalyst may be synthesized by any convenient method.

Catalyst Structures

Possible synthesis methods include coupling such as

Insertion such as

or by cyclometalation such as

wherein:

-   -   M=group 2-8 metal, preferably group 4 as a neutral or charged        moiety.    -   Y=any substituent including fused rings.    -   L=any ligating group, especially a pyridyl or pyridylamide.    -   X=alkyl, aryl, substituted alkyl, H or hydride, halide, or other        anionic moiety.    -   y=number to complete valence of M.    -   R=aklyl, aryl, haloalkyl, haloaryl, hydrogen, etc.    -   x=1-6, especially 2.    -   Dashed line=optional bond, especially a weak bond.    -   X and (CR₂)_(x) may be tethered or part of a ring.    -   E=any anionic moiety, (including alkyl or aryl) or H of a C—H        unit    -   Red=reducing agent.    -   a+b=number to complete the valence of Red when oxidized    -   c=number of equivalents of Red required to join (CR₂)_(x) to M

As one skilled in the art can appreciate it may also be desirable insome situations to use an in-situ synthesis method such that thecatalyst is formed during the polymerization reaction.

Cocatalysts

As one skilled in the art will appreciate it may be useful to combinethe pre-catalyst or synthesized catalyst with a suitable cocatalyst,preferably a cation forming cocatalyst, a strong Lewis acid, or acombination thereof. In a preferred embodiment, the shuttling agent, ifemployed, is employed both for purposes of chain shuttling and as thecocatalyst component of the catalyst composition.

The metal complexes desirably are rendered catalytically active bycombination with a cation forming cocatalyst, such as those previouslyknown in the art for use with Group 4 metal olefin polymerizationcomplexes. Suitable cation forming cocatalysts for use herein includeneutral Lewis acids, such as C₁₋₃₀ hydrocarbyl substituted Group 13compounds, especially tri(hydrocarbyl)aluminum or tri(hydrocarbyl)boroncompounds and halogenated (including perhalogenated) derivativesthereof, having from 1 to 10 carbons in each hydrocarbyl or halogenatedhydrocarbyl group, more especially perfluorinated tri(aryl)boroncompounds, and most especially tris(pentafluoro-phenyl)borane;nonpolymeric, compatible, noncoordinating, ion forming compounds(including the use of such compounds under oxidizing conditions),especially the use of ammonium-, phosphonium-, oxonium-, carbonium-,silylium- or sulfonium-salts of compatible, noncoordinating anions, orferrocenium-, lead- or silver salts of compatible, noncoordinatinganions; and combinations of the foregoing cation forming cocatalysts andtechniques. The foregoing activating cocatalysts and activatingtechniques have been previously taught with respect to different metalcomplexes for olefin polymerizations in the following references: EPPatent Publication No. 277,003; U.S. Pat. Nos. 5,153,157, 5,064,802,5,321,106, 5,721,185, 5,350,723, 5,425,872, 5,625,087, 5,883,204,5,919,983 and 5,783,512; and International Patent Publication Nos. WO99/15534 and WO 99/42467, all of which are incorporated herein byreference.

Combinations of neutral Lewis acids, especially the combination of atrialkyl aluminum compound having from 1 to 4 carbons in each alkylgroup and a halogenated tri(hydrocarbyl)boron compound having from 1 to20 carbons in each hydrocarbyl group, especiallytris(pentafluorophenyl)borane, further combinations of such neutralLewis acid mixtures with a polymeric or oligomeric alumoxane, andcombinations of a single neutral Lewis acid, especiallytris(pentafluorophenyl)borane with a polymeric or oligomeric alumoxanemay be used as activating cocatalysts. Preferred molar ratios of metalcomplex:tris(pentafluorophenyl-borane:alumoxane are from 1:1:1 to1:5:20, more preferably from 1:1:1.5 to 1:5:10.

Suitable ion forming compounds useful as cocatalysts in one embodimentof the present invention comprise a cation which is a Bronsted acidcapable of donating a proton, and a compatible, noncoordinating anion,A⁻. As used herein, the term “noncoordinating” means an anion orsubstance which either does not coordinate to the Group 4 metalcontaining precursor complex and the catalytic derivative derived therefrom, or which is only weakly coordinated to such complexes therebyremaining sufficiently labile to be displaced by a neutral Lewis base. Anoncoordinating anion specifically refers to an anion which whenfunctioning as a charge balancing anion in a cationic metal complex doesnot transfer an anionic substituent or fragment thereof to said cationthereby forming neutral complexes. “Compatible anions” are anions whichare not degraded to neutrality when the initially formed complexdecomposes and are noninterfering with desired subsequent polymerizationor other uses of the complex.

Preferred anions are those containing a single coordination complexcomprising a charge-bearing metal or metalloid core which anion iscapable of balancing the charge of the active catalyst species (themetal cation) which may be formed when the two components are combined.Also, said anion should be sufficiently labile to be displaced byolefinic, diolefinic and acetylenically unsaturated compounds or otherneutral Lewis bases such as ethers or nitriles.

Suitable metals include, but are not limited to, aluminum, gold andplatinum. Suitable metalloids include, but are not limited to, boron,phosphorus, and silicon. Compounds containing anions which comprisecoordination complexes containing a single metal or metalloid atom are,of course, well known and many, particularly such compounds containing asingle boron atom in the anion portion, are available commercially.

Preferably such cocatalysts may be represented by the following generalformula:(L*-H)_(g) ⁺(A)^(g−)wherein:

L* is a neutral Lewis base;

(L*-H)⁺ is a conjugate Bronsted acid of L*;

A^(g−) is a noncoordinating, compatible anion having a charge of g−, and

g is an integer from 1 to 3.

More preferably A^(g−) corresponds to the formula: [M′Q₄]⁻;

wherein:

-   -   M′ is boron or aluminum in the +3 formal oxidation state; and    -   Q independently each occurrence is selected from hydride,        dialkylamido, halide, hydrocarbyl, hydrocarbyloxide,        halosubstituted-hydrocarbyl, halosubstituted hydrocarbyloxy, and        halo-substituted silylhydrocarbyl radicals (including        perhalogenated hydrocarbyl-perhalogenated hydrocarbyloxy- and        perhalogenated silylhydrocarbyl radicals), said Q having up to        20 carbons with the proviso that in not more than one occurrence        is Q halide. Examples of suitable hydrocarbyloxide Q groups are        disclosed in U.S. Pat. No. 5,296,433.

In a more preferred embodiment, d is one, that is, the counter ion has asingle negative charge and is A⁻. Activating cocatalysts comprisingboron which are particularly useful in the preparation of catalysts ofthis invention may be represented by the following general formula:(L*-H)⁺(BQ₄)⁻;wherein:

-   -   L* is as previously defined;    -   B is boron in a formal oxidation state of 3; and    -   Q is a hydrocarbyl-, hydrocarbyloxy-, fluorinated hydrocarbyl-,        fluorinated hydrocarbyloxy-, or fluorinated        silylhydrocarbyl-group of up to 20 nonhydrogen atoms, with the        proviso that in not more than one occasion is Q hydrocarbyl.

Preferred Lewis base salts are ammonium salts, more preferablytrialkylammonium salts containing one or more C₁₂₋₄₀ alkyl groups. Mostpreferably, Q is each occurrence a fluorinated aryl group, especially, apentafluorophenyl group.

Illustrative, but not limiting, examples of boron compounds which may beused as an activating cocatalyst in the preparation of the improvedcatalysts of this invention are tri-substituted ammonium salts such as:

-   trimethylammonium tetrakis(pentafluorophenyl)borate,-   triethylammonium tetrakis(pentafluorophenyl)borate,-   tripropylammonium tetrakis(pentafluorophenyl)borate,-   tri(n-butyl)ammonium tetrakis(pentafluorophenyl)borate,-   tri(sec-butyl)ammonium tetrakis(pentafluorophenyl)borate,-   N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate,-   N,N-dimethylanilinium n-butyltris(pentafluorophenyl)borate,-   N,N-dimethylanilinium benzyltris(pentafluorophenyl)borate,-   N,N-dimethylanilinium    tetrakis(4-(t-butyldimethylsilyl)-2,3,5,6-tetrafluorophenyl)borate,-   N,N-dimethylanilinium    tetrakis(4-(triisopropylsilyl)-2,3,5,6-tetrafluorophenyl)borate,-   N,N-dimethylanilinium    pentafluorophenoxytris(pentafluorophenyl)borate,-   N,N-diethylanilinium tetrakis(pentafluorophenyl)borate,-   N,N-dimethyl-2,4,6-trimethylanilinium    tetrakis(pentafluorophenyl)borate,-   dimethyloctadecylammonium tetrakis(pentafluorophenyl)borate,-   methyldioctadecylammonium tetrakis(pentafluorophenyl)borate,    dialkyl ammonium salts such as:-   di-(i-propyl)ammonium tetrakis(pentafluorophenyl)borate,-   methyloctadecylammonium tetrakis(pentafluorophenyl)borate,-   methyloctadodecylammonium tetrakis(pentafluorophenyl)borate, and-   dioctadecylammonium tetrakis(pentafluorophenyl)borate;    tri-substituted phosphonium salts such as:-   triphenylphosphonium tetrakis(pentafluorophenyl)borate,-   methyldioctadecylphosphonium tetrakis(pentafluorophenyl)borate, and-   tri(2,6-dimethylphenyl)phosphonium    tetrakis(pentafluorophenyl)borate;    di-substituted oxonium salts such as:-   diphenyloxonium tetrakis(pentafluorophenyl)borate,-   di(o-tolyl)oxonium tetrakis(pentafluorophenyl)borate, and-   di(octadecyl)oxonium tetrakis(pentafluorophenyl)borate;    di-substituted sulfonium salts such as:-   di(o-tolyl)sulfonium tetrakis(pentafluorophenyl)borate, and-   methylcotadecylsulfonium tetrakis(pentafluorophenyl)borate.

Preferred (L*-H)⁺ cations are methyldioctadecylammonium cations,dimethyloctadecylammonium cations, and ammonium cations derived frommixtures of trialkyl amines containing one or 2 C₁₄₋₁₈ alkyl groups.

Another suitable ion forming, activating cocatalyst comprises a salt ofa cationic oxidizing agent and a noncoordinating, compatible anionrepresented by the formula:(Ox^(h+))_(g)(A^(g))_(h),wherein:

Ox^(h+) is a cationic oxidizing agent having a charge of h+;

h is an integer from 1 to 3; and

A^(g−) and g are as previously defined.

Examples of cationic oxidizing agents include: ferrocenium,hydrocarbyl-substituted ferrocenium, Ag⁺, or Pb⁺². Preferred embodimentsof A^(g−) are those anions previously defined with respect to theBronsted acid containing activating cocatalysts, especiallytetrakis(pentafluorophenyl)borate.

Another suitable ion forming, activating cocatalyst comprises a compoundwhich is a salt of a carbenium ion and a noncoordinating, compatibleanion represented by the formula:[C]⁺A⁻wherein:

-   -   [C]⁺ is a C₁₋₂₀ carbenium ion; and    -   A⁻ is a noncoordinating, compatible anion having a charge of −1.        A preferred carbenium ion is the trityl cation, that is        triphenylmethylium.

A further suitable ion forming, activating cocatalyst comprises acompound which is a salt of a silylium ion and a noncoordinating,compatible anion represented by the formula:(Q¹ ₃Si)⁺A⁻wherein:

Q¹ is C₁₋₁₀ hydrocarbyl, and A⁻ is as previously defined.

Preferred silylium salt activating cocatalysts are trimethylsilyliumtetrakispentafluorophenylborate, triethylsilyliumtetrakispentafluorophenylborate and ether substituted adducts thereof.Silylium salts have been previously generically disclosed in J. ChemSoc. Chem. Comm., 1993, 383-384, as well as Lambert, J. B., et al.,Organometallics, 1994, 13, 2430-2443. The use of the above silyliumsalts as activating cocatalysts for addition polymerization catalysts isdisclosed in U.S. Pat. No. 5,625,087.

Certain complexes of alcohols, mercaptans, silanols, and oximes withtris(pentafluorophenyl)borane are also effective catalyst activators andmay be used according to the present invention. Such cocatalysts aredisclosed in U.S. Pat. No. 5,296,433.

Suitable activating cocatalysts for use herein also include polymeric oroligomeric alumoxanes, especially methylalumoxane (MAO), triisobutylaluminum modified methylalumoxane (MMAO), or isobutylalumoxane; Lewisacid modified alumoxanes, especially perhalogenatedtri(hydrocarbyl)aluminum- or perhalogenated tri(hydrocarbyl)boronmodified alumoxanes, having from 1 to 10 carbons in each hydrocarbyl orhalogenated hydrocarbyl group, and most especiallytris(pentafluorophenyl)borane modified alumoxanes. Such cocatalysts arepreviously disclosed in U.S. Pat. Nos. 6,214,760, 6,160,146, 6,140,521,and 6,696,379.

A class of cocatalysts comprising non-coordinating anions genericallyreferred to as expanded anions, further disclosed in U.S. Pat. No.6,395,671, may be suitably employed to activate the metal complexes ofthe present invention for olefin polymerization. Generally, thesecocatalysts (illustrated by those having imidazolide, substitutedimidazolide, imidazolinide, substituted imidazolinide, benzimidazolide,or substituted benzimidazolide anions) may be depicted as follows:

wherein:

-   -   A*⁺ is a cation, especially a proton containing cation, and        preferably is a trihydrocarbyl ammonium cation containing one or        two C₁₀₋₄₀ alkyl groups, especially a methyldi        (C₁₄₋₂₀alkyl)ammonium cation,    -   Q³, independently each occurrence, is hydrogen or a halo,        hydrocarbyl, halocarbyl, halohydrocarbyl, silylhydrocarbyl, or        silyl, (including mono-, di- and tri(hydrocarbyl)silyl) group of        up to 30 atoms not counting hydrogen, preferably C₁₋₂₀ alkyl,        and    -   Q² is tris(pentafluorophenyl)borane or        tris(pentafluorophenyl)alumane).

Examples of these catalyst activators includetrihydrocarbylammonium-salts, especially,methyldi(C₁₄₋₂₀alkyl)ammonium-salts of:

-   bis(tris(pentafluorophenyl)borane)imidazolide,-   bis(tris(pentafluorophenyl)borane)-2-undecylimidazolide,-   bis(tris(pentafluorophenyl)borane)-2-heptadecylimidazolide,-   bis(tris(pentafluorophenyl)borane)-4,5-bis(undecyl)imidazolide,-   bis(tris(pentafluorophenyl)borane)-4,5-bis(heptadecyl)imidazolide,-   bis(tris(pentafluorophenyl)borane)imidazolinide,-   bis(tris(pentafluorophenyl)borane)-2-undecylimidazolinide,-   bis(tris(pentafluorophenyl)borane)-2-heptadecylimidazolinide,-   bis(tris(pentafluorophenyl)borane)-4,5-bis(undecyl)imidazolinide,-   bis(tris(pentafluorophenyl)borane)-4,5-bis(heptadecyl)imidazolinide,-   bis(tris(pentafluorophenyl)borane)-5,6-dimethylbenzimidazolide,-   bis(tris(pentafluorophenyl)borane)-5,6-bis(undecyl)benzimidazolide,-   bis(tris(pentafluorophenyl)alumane)imidazolide,-   bis(tris(pentafluorophenyl)alumane)-2-undecylimidazolide,-   bis(tris(pentafluorophenyl)alumane)-2-heptadecylimidazolide,-   bis(tris(pentafluorophenyl)alumane)-4,5-bis(undecyl)imidazolide,-   bis(tris(pentafluorophenyl)alumane)-4,5-bis(heptadecyl)imidazolide,-   bis(tris(pentafluorophenyl)alumane)imidazolinide,-   bis(tris(pentafluorophenyl)alumane)-2-undecylimidazolinide,-   bis(tris(pentafluorophenyl)alumane)-2-heptadecylimidazolinide,-   bis(tris(pentafluorophenyl)alumane)-4,5-bis(undecyl)imidazolinide,-   bis(tris(pentafluorophenyl)alumane)-4,5-bis(heptadecyl)imidazolinide,-   bis(tris(pentafluorophenyl)alumane)-5,6-dimethylbenzimidazolide, and-   bis(tris(pentafluorophenyl)alumane)-5,6-bis(undecyl)benzimidazolide.

Other activators include those described in PCT publication WO 98/07515such as tris(2,2′,2″-nonafluorobiphenyl)fluoroaluminate. Combinations ofactivators are also contemplated by the invention, for example,alumoxanes and ionizing activators in combinations, see for example,EP-A-0 573120, PCT publications WO 94/07928 and WO 95/14044 and U.S.Pat. Nos. 5,153,157 and 5,453,410. WO 98/09996 describes activatingcatalyst compounds with perchlorates, periodates and iodates, includingtheir hydrates. WO 99/18135 describes the use of organoboroaluminumactivators. WO 03/10171 discloses catalyst activators that are adductsof Bronsted acids with Lewis acids. Other activators or methods foractivating a catalyst compound are described in for example, U.S. Pat.Nos. 5,849,852, 5,859,653, 5,869,723, EP-A-615981, and PCT publicationWO 98/32775. All of the foregoing catalyst activators as well as anyother know activator for transition metal complex catalysts may beemployed alone or in combination according to the present invention,however, for best results alumoxane containing cocatalysts are avoided.

The molar ratio of catalyst/cocatalyst employed preferably ranges from1:10,000 to 100:1, more preferably from 1:5000 to 10:1, most preferablyfrom 1:1000 to 1:1. Alumoxane, when used by itself as an activatingcocatalyst, is employed in large quantity, generally at least 100 timesthe quantity of metal complex on a molar basis.Tris(pentafluorophenyl)borane, where used as an activating cocatalyst isemployed in a molar ratio to the metal complex of from 0.5:1 to 10:1,more preferably from 1:1 to 6:1 most preferably from 1:1 to 5:1. Theremaining activating cocatalysts are generally employed in approximatelyequimolar quantity with the metal complex.

Novel Compositions of the Present Invention

Advantageously, novel compositions of the present invention comprise anethylene/alpha-olefin interpolymer composition with a multi-modalmolecular weight distribution and one or more molecules having a grammolecular weight equal to about ((the molecular weight of an aryl orhydrocarbyl-ligand of a pre-catalyst)+28+14*X), wherein X represents aninteger from zero to 10, preferably zero to 8. The aryl or hydrocarbylligand may be any of those described herein. The molecule may beobserved in the composition by extracting the interpolymer with asolvent such as methylene chloride, adding another solvent such as analcohol, e.g. ethanol, and decanting. The decantate can then be analyzedby any convenient analytical method such as gas chromatography coupledwith mass spectroscopy. Said composition may also contain ethylene, anα-olefin, a reaction product or a mixture thereof.

Other novel compositions of the present invention include the catalystwhich may be synthesized as described above optionally mixed withethylene, an α-olefin, a reaction product or a mixture thereof.

Ethylene/α-Olefin Multi-Block Interpolymer Component(s)

The general processes described above may also be used to produce anethylene/α-olefin multi-block interpolymer such as those describe in,for example, copending U.S. application Ser. No. 11/376,835 filed onMar. 15, 2006 and PCT Publication No. WO 2005/090427, filed on Mar. 17,2005, which in turn claims priority to U.S. Provisional Application No.60/553,906, filed Mar. 17, 2004. For purposes of United States patentpractice, the contents of the aforementioned applications are hereinincorporated by reference in their entirety. If such a multi-blockpolymer is desired then the processes described above will alsogenerally include a catalyst such as one comprising zinc which isdifferent than any pre-catalyst that may be employed. In addition, ashuttling agent such as diethyl zinc or others described in PCTPublication No. WO 2005/090427 may be employed. Such processes mayresult in a polymer wherein the polymer has one or more of the followingcharacteristics:

(1) an average block index greater than zero and up to about 1.0 and amolecular weight distribution, Mw/Mn, greater than about 1.3; or

(2) at least one molecular fraction which elutes between 40° C. and 130°C. when fractionated using TREF, characterized in that the fraction hasa block index of at least 0.5 and up to about 1; or

(3) an Mw/Mn from about 1.7 to about 3.5, at least one melting point,Tm, in degrees Celsius, and a density, d, in grams/cubic centimeter,wherein the numerical values of Tm and d correspond to the relationship:T _(m)>−2002.9+4538.5(d)−2422.2(d)²,preferablyT _(m)≧858.91−1825.3(d)+1112.8(d)²; or

(4) an Mw/Mn from about 1.7 to about 3.5, and is characterized by a heatof fusion, ΔH in J/g, and a delta quantity, ΔT, in degrees Celsiusdefined as the temperature difference between the tallest DSC peak andthe tallest CRYSTAF peak, wherein the numerical values of ΔT and ΔH havethe following relationships:ΔT>−0.1299(ΔH)+62.81 for ΔH greater than zero and up to 130 J/g,ΔT≧48° C. for ΔH greater than 130 J/g,

wherein the CRYSTAF peak is determined using at least 5 percent of thecumulative polymer, and if less than 5 percent of the polymer has anidentifiable CRYSTAF peak, then the CRYSTAF temperature is 30° C.; or

(5) an elastic recovery, Re, in percent at 300 percent strain and 1cycle measured with a compression-molded film of the ethylene/α-olefininterpolymer, and has a density, d, in grams/cubic centimeter, whereinthe numerical values of Re and d satisfy the following relationship whenethylene/α-olefin interpolymer is substantially free of a cross-linkedphase:Re>1481−1629(d); or

(6) a molecular fraction which elutes between 40° C. and 130° C. whenfractionated using TREF, characterized in that the fraction has a molarcomonomer content of at least 5 percent higher than that of a comparablerandom ethylene interpolymer fraction eluting between the sametemperatures, wherein said comparable random ethylene interpolymer hasthe same comonomer(s) and has a melt index, density, and molar comonomercontent (based on the whole polymer) within 10 percent of that of theethylene/α-olefin interpolymer; or

(7) a storage modulus at 25° C., G′(25° C.), and a storage modulus at100° C., G′(100° C.), wherein the ratio of G′(25° C.) to G′(100° C.) isin the range of about 1:1 to about 9:1; or

(8) has a DSC melting curve characterized by an area under the DSCmelting curve from the melting peak temperature to the end of melting isat least about 17%, at least about 18%, at least about 19%, at leastabout 21%, at least about 23%, at least about 25%, at least about 27%,at least about 29%, at least about 31%, at least about 33%, to at most25, preferably 35% of the total area under the DSC melting curve from−20° C. to the end of melting or

(9) has a B value of greater than about 0.98, greater than about 0.99,greater than about 1.0 or greater than about 1.02.

It has been found that when a cocatalyst shuttling agent, e.g. diethylzinc, is employed interpolymers having improved residual enthalpy andhot tack are often made. In addition, it has also been observed that theinterpolymers may be manufactured to have little or no long chainbranching. When a shuttling agent is not employed, improved properties,e.g., Dart impact, tear, puncture resistance may be observed.

The interpolymers of and used in the present invention preferably have adensity in the range of from about 0.875 g/cc to about 0.915 g/cc,preferably from about 0.895 g/cc to about 0.910 g/cc; a molecular weightdistribution in the range from about 2.0 to about 3.8, from about 2.2 toabout 3.5, from about 2.2 to about 3.3, or from about 2.2 to about 3.8;an I₁₀/I₂ in the range from about 5.5 to about 6.5, preferably fromabout 5.6 to about 6.3; an I₂ melt index in the range from about 0.2 toabout 20.

The B-values of the interpolymers of the present invention often have aB value of greater than about 0.98, greater than about 0.99, greaterthan about 1.0 or greater than about 1.02. “B-value” and similar termsmean the ethylene units of an ethylene/α-olefin interpolymer aredistributed across the polymer chain in a nonrandom manner. B-valuesrange from 0 to 2. The higher the B-value, the more alternating thecomonomer distribution in the copolymer. The lower the B-value, the moreblocky or clustered the comonomer distribution in the copolymer.

There are several ways to calculate B-value; the method described belowutilizes the method of Koenig, J. L., where a B-value of 1 designates aperfectly random distribution of comonomer units. The B-value asdescribed by Koenig is calculated as follows. B is defined for anethylene/α-olefin interpolymer as an index of composition distributionof constituent units derived from each monomer in the interpolymerchain, and can be calculated from the following formula:

$B = \frac{P_{EO}}{2{P_{O} \cdot P_{E}}}$

wherein P_(E) and P_(O) are respectively a molar fraction of theethylene component and a molar fraction of the α-olefin (e.g., octene)component contained in the ethylene/α-olefin interpolymer such asethylene/octene interpolymer; and P_(EO) is a molar fraction of theethylene/α-olefin chain such as ethylene/octene chain in all the dyadchains.

In some embodiments, the values of P_(O), P_(B) and P_(EO) for anethylene/α-olefin interpolymer such as ethylene/octene interpolymer canbe obtained in the following manner. In a sample tube having a diameterof 10 mm, about 200 mg of the ethylene/α-olefin interpolymer ishomogeneously dissolved in 1 ml of hexachlorobutadiene to give a sample,and a ¹³C-NMR spectrum of the sample is measured according to literaturereferences, such as G. J. Ray (Macromolecules, 10, 773, 1977) and J. C.Randall (Macromolecules, 15, 353, 1982; J. Polymer Science, PolymerPhysics Ed., 11, 275, 1973), and K. Kimura (Polymer, 25, 441, 1984). Bvalues are also discussed in the publication WO 2006/069205 A1 publishedJun. 29, 2006 and incorporated herein by reference. The B value is 2when the ethylene/α-olefin interpolymer such as ethylene/octeneinterpolymer is a perfectly alternating interpolymer, while the B valueis 0 when the interpolymer is a perfectly block interpolymer.

The ethylene/α-olefin interpolymers of the present invention, e.g.ethylene-octene, advantageously can be made using less α-olefin, e.g.octene, than prior polymers yet the interpolymers of the presentinvention have approximately the same or higher density. This is shownin, for example, FIG. 29 which shows that the ethylene/α-olefininterpolymers of the present invention often comprise one or more of thefollowing characteristics: a density in g/cc, d, and a weight percentα-olefin, Wt. %, wherein the numerical values of d and Wt. % correspondto the relationship: d≦−0.0018 Wt. %+0.9297 and/or d≦−0.0019 Wt.%+0.933. This is a surprising and unexpected relationship in thattypically the density will decrease more with decreasing amounts ofα-olefin. It has been discovered that the use of a shuttling agent mayaffect the aforementioned relationships. For example, the interpolymersmade with a shuttling agent such as diethyl zinc often exhibit therelationship: d≦−0.0018 Wt. %+0.9297 whereas interpolymers made withouta shuttling agent such as diethyl zinc often exhibit the relationship:d≦−0.0019 Wt. %+0.933. FIG. 29 is a plot showing the density of anethylene/α-olefin interpolymer as a function of the weight percentage of1-octene for inventive polymers made using diethyl zinc (DEZ) andinventive polymers made without using DEZ.

Applications and End Uses

The polymers of the present invention can be used in a variety ofconventional thermoplastic fabrication processes to produce usefularticles. Such articles include objects comprising at least one filmlayer, such as a monolayer film, or at least one layer in a multilayerfilm prepared by cast, blown, calendered, or extrusion coatingprocesses; molded articles, such as blow molded, injection molded, orrotomolded articles; extrusions; fibers; and woven or non-woven fabrics.

Due to the surprising and unexpected hot tack properties, as well as,the puncture and Dart impact properties the polymers and compositions ofthe present invention are particularly suited for food applications suchas form, fill and seal applications. Film layers of the presentinvention may often be made wherein the average hot tack (ASTM F 1921,Method B, dwell time of 500 ms, seal pressure of 27.5 N/cm²) is at least10 N over a temperature range of at least 20° C., preferably 25° C.,more preferably 28° C. Heat sealable films made with the composition ofthe present invention may be employed in either monolayer or multilayerfilm structures or as laminates. Regardless of how the film is utilized,it may be prepared by a variety of processes that are well known tothose of skill in the art.

Film structures may be made by conventional fabrication techniques, e.g.simple bubble extrusion, biaxial orientation processes (such as tenterframes or double bubble processes), simple cast/sheet extrusion,coextrusion, lamination, etc. Conventional simple bubble extrusionprocesses (also known as hot blown film processes) are described, forexample, in The Encyclopedia of Chemical Technology, Kirk-Othmer, ThirdEdition, John Wiley & Sons, New York, 1981, Vol. 16, pp. 416-417 andVol. 18, pp. 191-192, the disclosures of which are incorporated hereinby reference. Biaxial orientation film manufacturing processes such asdescribed in the “double bubble” process of U.S. Pat. No. 3,456,044(Pahlke), and the processes described in U.S. Pat. No. 4,352,849(Mueller), U.S. Pat. Nos. 4,820,557 and 4,837,084 (both to Warren), U.S.Pat. No. 4,865,902 (Golike et al.), U.S. Pat. No. 4,927,708 (Herran etal.), U.S. Pat. No. 4,952,451 (Mueller), and U.S. Pat. Nos. 4,963,419and 5,059,481 (both to Lustig et al.), the disclosures of which areincorporated herein by reference, can also be used to make the novelfilm structures of this invention. Biaxially oriented film structurescan also be made by a tenter-frame technique, such as that used fororiented polypropylene.

Other multilayer film manufacturing techniques for food packagingapplications are described in Packaging Foods With Plastics by Wilmer A.Jenkins and James P. Harrington (1991), pp. 19-27, and in “CoextrusionBasics” by Thomas I. Butler, Film Extrusion Manual: Process, Materials,Properties. pp. 31-80 (published by TAPPI Press (1992)) the disclosuresof which are incorporated herein by reference.

In certain embodiments of this invention, at least one heat sealable,innermost or outermost layer (i.e., sealing or skin layer) of a filmstructure comprises the polymers of the present invention. This heatsealable layer can be coextruded with other layer(s) or the heatsealable layer can be laminated onto another layer(s) or substrate in asecondary operation, such as that described in Packaging Foods WithPlastics, ibid, or that described in “Coextrusion For Barrier Packaging”by W. J. Schrenk and C. R. Finch, Society of Plastics Engineers RETECProceedings Jun. 15-17, 1981, pp. 211-229, the disclosures of which areincorporated herein by reference. Preferable substrates include papers,foils, oriented polypropylenes, polyamides, polyesters, polyethylenes,polyethylene terephthalate, and, metallized substrates.

Should a multilayer film be desired, such may be obtained from amonolayer film which has been previously produced via tubular film(i.e., blown film techniques) or flat die (i.e. cast film) as describedby K. R. Osborn and W. A. Jenkins in “Plastic Films, Technology andPackaging Applications” (Technomic Publishing Co., Inc. (1992)), thedisclosures of which are incorporated herein by reference, wherein thesealant film must go through an additional post-extrusion step ofadhesive or extrusion lamination to other packaging material layers. Ifthe sealant film is a coextrusion of two or more layers (also describedby Osborn and Jenkins), the film may still be laminated to additionallayers of packaging materials, depending on the other physicalrequirements of the final packaging film. “Laminations vs. Coextrusions”by D. Dumbleton (Converting Magazine, September 1992), the disclosure ofwhich is incorporated herein by reference, also discusses laminationversus coextrusion. Monolayer and coextruded films can also go throughother post-extrusion techniques, such as a biaxial orientation processand irradiation. With respect to irradiation, this technique can alsoprecede extrusion by irradiating the pellets from which the film is tobe fabricated prior to feeding the pellets into the extruder, whichincreases the melt tension of the extruded polymer film and enhancesprocessability.

Extrusion coating is yet another technique for producing packagingmaterials. Similar to cast film, extrusion coating is a flat dietechnique. A heat-sealable film comprised of the compositions of thepresent invention can be extrusion coated onto a substrate either in theform of a monolayer or a coextruded extrudate according to, for example,the processes described in U.S. Pat. No. 4,339,507 incorporated hereinby reference. Utilizing multiple extruders or by passing the varioussubstrates through the extrusion coating system several times can resultin multiple polymer layers each providing some sort of performanceattribute whether it be barrier, toughness, or improved hot tack or heatsealability. Some typical end use applications formulti-layered/multi-substrate systems are for cheese packages. Other enduse applications include, but are not limited to moist pet foods,snacks, chips, frozen foods, meats, hot dogs, and numerous otherapplications.

In those embodiments in which the film comprises one or more of thepolymers of the present invention, other layers of the multilayerstructure may be included to provide a variety of performanceattributes. These layers can be constructed from various materials,including blends of homogeneous linear or substantially linear ethylenepolymers with polypropylene polymers, and some layers can be constructedof the same materials, e.g some films can have the structure A/B/C/B/Awherein each different letter represents a different composition.Representative, nonlimiting examples of materials in other layers are:poly(ethylene terephthalate) (PET), ethylene/vinyl acetate (EVA)copolymers, ethylene/acrylic acid (BAA) copolymers, ethylene/methacrylicacid (EMAA) copolymers, LLDPE, HDPE, LDPE, graft-modified ethylenepolymers (e.g maleic anhydride grafted polyethylene), styrene-butadienepolymers (such as K-resins, available from Phillips Petroleum), etc.Generally, multilayer film structures comprise from 2 to about 7 layers.

The thickness of the multilayer structures is typically from about 1 milto about 4 mils (total thickness). The heat sealable film layer variesin thickness depending on whether it is produced via coextrusion orlamination of a monolayer or coextruded film to other packagingmaterials. In a coextrusion, the heat sealable film layer is typicallyfrom about 0.1 to about 3 mils, preferably from about 0.4 to about 2mils. In a laminated structure, the monolayer or coextruded heatsealable film layer is typically from about 0.5 to about 2 mils,preferably from about 1 to 2 mils. For a monolayer film, the thicknessis typically between about 0.4 mil to about 4 mils, preferably betweenabout 0.8 to about 2.5 mils.

The heat sealable films of the invention can be made into packagingstructures such as form-fill-seal structures or bag-in-box structures.For example, one such form-fill-seal operation is described in PackagingFoods With Plastics, ibid, pp. 78-83. Packages can also be formed frommultilayer packaging roll stock by vertical or horizontal form-fill-sealpackaging and thermoform-fill-seal packaging, as described in “PackagingMachinery Operations: No. 8, Form-Fill-Sealing, A Self-InstructionalCourse” by C. G. Davis, Packaging Machinery Manufacturers Institute(April 1982); The Wiley Encyclopedia of Packaging Technology by M.Bakker (Editor), John Wiley & Sons (1986), pp. 334, 364-369; andPackaging: An Introduction by S. Sacharow and A. L. Brody, HarcourtBrace Javanovich Publications, Inc. (1987), pp. 322-326. The disclosuresof all of the preceding publications are incorporated herein byreference. A particularly useful device for form-fill-seal operations isthe Hayssen Ultima Super CMB Vertical Form-Fill-Seal Machine. Othermanufacturers of pouch thermoforming and evacuating equipment includeCryovac and Koch. A process for making a pouch with a verticalform-fill-seal machine is described generally in U.S. Pat. Nos.4,503,102 and 4,521,437, both of which are incorporated herein byreference. Film structures containing one or more layers comprising aheat sealable film of the present invention are well suited for thepackaging of potable water, wine, cheese, potatoes, condiments, andsimilar food products in such form-fill-seal structures.

The films of the invention can be cross-linked, before or afterorientation, by any means known in the art, including, but not limitedto, electron-beam irradiation, beta irradiation, gamma irradiation,corona irradiation, silanes, peroxides, allyl compounds and UV radiationwith or without crosslinking catalyst. U.S. Pat. Nos. 6,803,014 and6,667,351 disclose electron-beam irradiation methods that can be used inembodiments of the invention.

Irradiation may be accomplished by the use of high energy, ionizingelectrons, ultra violet rays, X-rays, gamma rays, beta particles and thelike and combination thereof. Preferably, electrons are employed up to70 megarads dosages. The irradiation source can be any electron beamgenerator operating in a range of about 150 kilovolts to about 6megavolts with a power output capable of supplying the desired dosage.The voltage can be adjusted to appropriate levels which may be, forexample, 100,000, 300,000, 1,000,000 or 2,000,000 or 3,000,000 or6,000,000 or higher or lower. Many other apparati for irradiatingpolymeric materials are known in the art. The irradiation is usuallycarried out at a dosage between about 3 megarads to about 35 megarads,preferably between about 8 to about 20 megarads. Further, theirradiation can be carried out conveniently at room temperature,although higher and lower temperatures, for example 0° C. to about 60°C., may also be employed. Preferably, the irradiation is carried outafter shaping or fabrication of the article, such as a film. Also, in apreferred embodiment, the ethylene interpolymer which has beenincorporated with a pro-rad additive is irradiated with electron beamradiation at about 8 to about 20 megarads.

Crosslinking can be promoted with a crosslinking catalyst, and anycatalyst that will provide this function can be used. Suitable catalystsgenerally include organic bases, carboxylic acids, and organometalliccompounds including organic titanates and complexes or carboxylates oflead, cobalt, iron, nickel, zinc and tin. Dibutyltindilaurate,dioctyltinmaleate, dibutyltindiacetate, dibutyltindioctoate, stannousacetate, stannous octoate, lead naphthenate, zinc caprylate, cobaltnaphthenate; and the like. Tin carboxylate, especiallydibutyltindilaurate and dioctyltinmaleate, are particularly effective.The catalyst (or mixture of catalysts) is present in a catalytic amount,typically between about 0.015 and about 0.035 phr.

Representative pro-rad additives include, but are not limited to, azocompounds, organic peroxides and polyfunctional vinyl or allyl compoundssuch as, for example, triallyl cyanurate, triallyl isocyanurate,pentaerthritol tetramethacrylate, glutaraldehyde, ethylene glycoldimethacrylate, diallvl maleate, dipropargyl maleate, dipropargylmonoallyl cyanurate, dicumyl peroxide, di-tert-butyl peroxide, t-butylperbenzoate, benzoyl peroxide, cumene hydroperoxide, t-butyl peroctoate,methyl ethyl ketone peroxide, 2,5-dimethyl-2,5-di(t-butyl peroxy)hexane,lauryl peroxide, tert-butyl peracetate, azobisisobutyl nitrite and thelike and combination thereof. Preferred pro-rad additives for use insome embodiments of the invention are compounds which havepoly-functional (i.e. at least two) moieties such as C═C, C═N or C═O.

At least one pro-rad additive can be introduced to the ethyleneinterpolymer by any method known in the art. However, preferably thepro-rad additive(s) is introduced via a masterbatch concentratecomprising the same or different base resin as the ethyleneinterpolymer. Preferably, the pro-rad additive concentration for themasterbatch is relatively high e.g., about 25 weight percent (based onthe total weight of the concentrate).

The at least one pro-rad additive is introduced to the ethylene polymerin any effective amount. Preferably, the at least one pro-rad additiveintroduction amount is from about 0.001 to about 5 weight percent, morepreferably from about 0.005 to about 2.5 weight percent and mostpreferably from about 0.015 to about 1 weight percent (based on thetotal weight of the ethylene interpolymer.

In addition to electron-beam irradiation, crosslinking can also beeffected by UV irradiation. U.S. Pat. No. 6,709,742 discloses across-linking method by UV irradiation which can be used in embodimentsof the invention. The method comprises mixing a photoinitiator, with orwithout a photocrosslinker, with a polymer before, during, or after afiber is formed and then exposing the fiber with the photoinitiator tosufficient UV radiation to crosslink the polymer to the desired level.The photoinitiators used in the practice of the invention are aromaticketones, e.g., benzophenones or monoacetals of 1,2-diketones. Theprimary photoreaction of the monacetals is the homolytic cleavage of thea-bond to give acyl and dialkoxyalkyl radicals. This type of a-cleavageis known as a Norrish Type I reaction which is more fully described inW. Horspool and D. Armesto, Organic Photochemistry: A ComprehensiveTreatment, Ellis Horwood Limited, Chichester, England, 1992; J. Kopecky,Organic Photochemistry: A Visual Approach, VCH Publishers, Inc., NewYork, N.Y. 1992; N. J. Turro, et al., Acc. Chem. Res., 1972, 5, 92; andJ. T. Banks, et al., J. Am. Chem. Soc., 1993, 115, 2473. The synthesisof monoacetals of aromatic 1,2 diketones, Ar—CO—C(OR)₂—Ar′ is describedin U.S. Pat. No. 4,190,602 and Ger. Offen. 2,337,813. The preferredcompound from this class is 2,2-dimethoxy-2-phenylacetophenone,C₆H₅—CO—C(OCH₃)₂—C₆H₅, which is commercially available from Ciba-Geigyas Irgacure 651. Examples of other aromatic ketones useful asphotoinitiators are Irgacure 184, 369, 819, 907 and 2959, all availablefrom Ciba-Geigy.

In one embodiment of the invention, the photoinitiator is used incombination with a photocrosslinker. Any photocrosslinker that will uponthe generation of free radicals, link two or more olefin polymerbackbones together through the formation of covalent bonds with thebackbones can be used. Preferably these photocrosslinkers arepolyfunctional, i.e., they comprise two or more sites that uponactivation will form a covalent bond with a site on the backbone of thecopolymer. Representative photocrosslinkers include, but are not limitedto polyfunctional vinyl or allyl compounds such as, for example,triallyl cyanurate, triallyl isocyanurate, pentaerthritoltetramethacrylate, ethylene glycol dimethacrylate, diallyl maleate,dipropargyl maleate, dipropargyl monoallyl cyanurate and the like.Preferred photocrosslinkers for use in some embodiments of the inventionare compounds which have polyfunctional (i.e. at least two) moieties.Particularly preferred photocrosslinkers are triallycyanurate (TAC) andtriallylisocyanurate (TAIC).

Certain compounds act as both a photoinitiator and a photocrosslinker.These compounds are characterized by the ability to generate two or morereactive species (e.g., free radicals, carbenes, nitrenes, etc.) uponexposure to UV-light and to subsequently covalently bond with twopolymer chains. Any compound that can preform these two functions can beused in some embodiments of the invention, and representative compoundsinclude the sulfonyl azides described in U.S. Pat. Nos. 6,211,302 and6,284,842.

In another embodiment of this invention, the copolymer is subjected tosecondary crosslinking, i.e., crosslinking other than and in addition tophotocrosslinking. In this embodiment, the photoinitiator is used eitherin combination with a nonphotocrosslinker, e.g., a silane, or thecopolymer is subjected to a secondary crosslinking procedure, e.g,exposure to E-beam radiation. Representative examples of silanecrosslinkers are described in U.S. Pat. No. 5,824,718, and crosslinkingthrough exposure to E-beam radiation is described in U.S. Pat. Nos.5,525,257 and 5,324,576. The use of a photocrosslinker in thisembodiment is optional.

At least one photoadditive, i.e., photoinitiator and optionalphotocrosslinker, can be introduced to the copolymer by any method knownin the art. However, preferably the photoadditive(s) is (are) introducedvia a masterbatch concentrate comprising the same or different baseresin as the copolymer. Preferably, the photoadditive concentration forthe masterbatch is relatively high e.g., about 25 weight percent (basedon the total weight of the concentrate).

The at least one photoadditive is introduced to the copolymer in anyeffective amount. Preferably, the at least one photoadditiveintroduction amount is from about 0.001 to about 5, more preferably fromabout 0.005 to about 2.5 and most preferably from about 0.015 to about1, wt % (based on the total weight of the copolymer).

The photoinitiator(s) and optional photocrosslinker(s) can be addedduring different stages of the film manufacturing process. Ifphotoadditives can withstand the extrusion temperature, an olefinpolymer resin can be mixed with additives before being fed into theextruder, e.g., via a masterbatch addition. Alternatively, additives canbe introduced into the extruder just prior the slot die, but in thiscase the efficient mixing of components before extrusion is important.In another approach, olefin polymer films can be oriented withoutphotoadditives, and a photoinitiator and/or photocrosslinker can beapplied to the extruded film via a kiss-roll, spray, dipping into asolution with additives, or by using other industrial methods forpost-treatment. The resulting film with photoadditive(s) is then curedvia electromagnetic radiation in a continuous or batch process. Thephoto additives can be blended with an olefin polymer using conventionalcompounding equipment, including single and twin-screw extruders.

The power of the electromagnetic radiation and the irradiation time arechosen so as to allow efficient crosslinking without polymer degradationand/or dimensional defects. The preferred process is described in EP 0490 854 B1. Photoadditive(s) with sufficient thermal stability is (are)premixed with an olefin polymer resin, extruded into a film, andirradiated in a continuous process using one energy source or severalunits linked in a series. There are several advantages to using acontinuous process compared with a batch process to cure a film.

Irradiation may be accomplished by the use of UV-radiation. Preferably,UV-radiation is employed up to the intensity of 100 J/cm². Theirradiation source can be any UV-light generator operating in a range ofabout 50 watts to about 25000 watts with a power output capable ofsupplying the desired dosage. The wattage can be adjusted to appropriatelevels which may be, for example, 1000 watts or 4800 watts or 6000 wattsor higher or lower. Many other apparati for UV-irradiating polymericmaterials are known in the art. The irradiation is usually carried outat a dosage between about 3 J/cm² to about 500 J/scm², preferablybetween about 5 J/cm² to about 100 J/cm². Further, the irradiation canbe carried out conveniently at room temperature, although higher andlower temperatures, for example 0° C. to about 60° C., may also beemployed. The photocrosslinking process is faster at highertemperatures. Preferably, the irradiation is carried out after shapingor fabrication of the article. In a preferred embodiment, the copolymerwhich has been incorporated with a photoadditive is irradiated withUV-radiation at about 10 J/cm² to about 50 J/cm².

The polymers described herein are also useful for wire and cable coatingoperations, as well as in sheet extrusion for vacuum forming operations,and forming molded articles, including the use of injection molding,blow molding process, or rotomolding processes. Compositions comprisingthe olefin polymers can also be formed into fabricated articles such asthose previously mentioned using conventional polyolefin processingtechniques which are well known to those skilled in the art ofpolyolefin processing. Dispersions, both aqueous and non-aqueous, canalso be formed using the polymers or formulations comprising the same.Frothed foams comprising the invented polymers can also be formed, asdisclosed in PCT application No. PCT/US2004/027593, filed Aug. 25, 2004,and published as WO2005/021622. The polymers may also be crosslinked byany known means, such as the use of peroxide, electron beam, silane,azide, or other cross-linking technique. The polymers can also bechemically modified, such as by grafting (for example by use of maleicanhydride (MAH), silanes, or other grafting agent), halogenation,amination, sulfonation, or other chemical modification.

Suitable end uses for the foregoing products include elastic films andfibers; soft touch goods, such as tooth brush handles and appliancehandles; antiblocking compositions; cap liners, gaskets and profiles;adhesives (including hot melt adhesives and pressure sensitiveadhesives); footwear (including shoe soles and shoe liners); autointerior parts and profiles; foam goods (both open and closed cell);impact modifiers for other thermoplastic polymers; coated fabrics;hoses; tubing; weather stripping; cap liners; flooring; and viscosityindex modifiers, also known as pour point modifiers, for lubricants.

EXAMPLES

As stated above, the bimodal molecular weight “split” of the polymer maybe selected by controlling the mole fractions (f) of the two or moremonomers, n, such that the mole fraction of monomer m is defined as:

$f_{m} = {\frac{\left\lbrack {Momomer}_{m} \right\rbrack}{\sum\limits_{i = 1}^{n}\left\lbrack {Monomer}_{i} \right\rbrack}.}$

This may be quantified for an ethylene-octene copolymer as depicted inFIGS. 20 and 21. At low f₂, the low molecular weight fractionpredominates, but at higher f₂, the higher molecular weight species ismore prevalent.

General Experimental Considerations

Unless specified otherwise, all reagents are handled under anaerobicconditions using standard procedures for the handling of extremely air-and water-sensitive materials. Solvents are used without furtherpurification. All other chemicals are commercial materials and are usedas received.

General Reactor Polymerization Procedure

A one-gallon AE autoclave is purged at high temperature with N₂. ISOPAR®E was added, and the reactor is heated to 120° C. 1-Octene and hydrogenare added batchwise to the reactor and are not regulated during the run.The reactor is then pressurized with ethylene (450 psi). Solutions ofthe pre-catalyst, cocatalyst (1.2 equivalents to pre-catalyst), and ascavenger (5 equivalents to pre-catalyst) are mixed and then added tothe reactor using a flush of high pressure ISOPAR® E. Polymer yield iskept low to minimize monomer composition drift during the experiment.After the prescribed reaction time, reactor contents are dumped into aresin kettle and mixed with IRGANOX® 1010/IRGAFOS® 168 stabilizermixture (1 g). The polymer is recovered by evaporating the majority ofthe solvent at room temperature and then dried further in a vacuum ovenovernight at 90° C. Following the run, the reactor is hot-flushed withISOPAR® E to prevent polymer contamination from run to run.

TABLE 1 Batch reactor ethylene/octene copolymerization withPre-catalyst. Pre- ISOPAR ® Octene catalyst* E Ethylene feed YieldExample (mol) feed (g) feed (g) (g) f₂ (g) 1 2.0 1591 153 11 0.02 44 22.0 1550 151 56 0.10 41 3 2.0 1506 153 100 0.16 46 4 2.5 1402 167 2030.31 26 5 2.5 1201 168 400 0.47 36 6 2.5 1009 170 605 0.57 44 7 3.0 812169 801 0.64 66 8 3.0 611 165 1003 0.69 60 9 3.0 401 166 1202 0.73 64 103.0 204 166 1402 0.75 52 11 3.5 10 168 1603 0.78 84 M_(w) M_(n) Example(kg/mol) (kg/mol) M_(w)/M_(n) 1 671 174 3.86 2 588 164 3.59 3 517 1393.71 4 851 116 7.35 5 972 137 7.10 6 906 164 5.51 7 1015 169 6.02 8 1108232 4.78 9 1135 202 5.62 10 1148 239 4.81 11 1013 177 5.74 ^(a)Polymerization conditions: 1.2 equiv. co-catalyst, T = 120° C., 460 psigreactor pressure, 40 mmol hydrogen, t = 10 min. *Pre-catalyst =[N-(2,6-di(1-methylethyl)phenyl)amido)(2-isopropylphenyl)(α-naphthalen-2-diyl(6-pyridin-2-diyl)methane)]hafniumdimethyl (as disclosed in U.S. Application No. 20040220050) and aco-catalyst of methyldi(C₁₄₋₁₈alkyl) ammonium salts oftetrakis(pentafluorophenyl)borate (as disclosed in U.S. Pat. No.5,919,983).

Examples 12-15 Continuous Solution Polymerization, Catalyst A1

Continuous solution polymerizations are carried out in a computercontrolled autoclave reactor equipped with an internal stirrer. Purifiedmixed alkanes solvent (ISOPAR® E available from ExxonMobil, Inc.),ethylene, 1-octene, and hydrogen (where used) are supplied to a reactorequipped with a jacket for temperature control and an internalthermocouple. The solvent feed to the reactor is measured by a mass-flowcontroller. A variable speed diaphragm pump controls the solvent flowrate and pressure to the reactor. At the discharge of the pump, a sidestream is taken to provide flush flows for the catalyst and cocatalyst 1injection lines and the reactor agitator. These flows are measured byMicro-Motion mass flow meters and controlled by control valves or by themanual adjustment of needle valves. The remaining solvent is combinedwith 1-octene, ethylene, and hydrogen (where used) and fed to thereactor. A mass flow controller is used to deliver hydrogen to thereactor as needed. The temperature of the solvent/monomer solution iscontrolled by use of a heat exchanger before entering the reactor. Thisstream enters the bottom of the reactor. The catalyst componentsolutions are metered using pumps and mass flow meters and are combinedwith the catalyst flush solvent and introduced into the bottom of thereactor. The reactor is run liquid-full at 500 psig (3.45 MPa) withvigorous stirring. Product is removed through exit lines at the top ofthe reactor. All exit lines from the reactor are steam traced andinsulated. Polymerization is stopped by the addition of a small amountof water into the exit line along with any stabilizers or otheradditives and passing the mixture through a static mixer. The productstream is then heated by passing through a heat exchanger beforedevolatilization. The polymer product is recovered by extrusion using adevolatilizing extruder and water cooled pelletizer. Process details andresults are contained in Table 2. Selected polymer properties areprovided in Table 3.

TABLE 2 Pre- Pre- cat cat Al Cocat Cocat MMAO MMAO Poly C₂H₄ C₈H₁₆ Solv.H₂ T Al² Flow Conc. Flow Conc. Flow Rate³ Conv Solids Ex. kg/hr kg/hrkg/hr sccm¹ ° C. ppm Kg/hr ppm kg/hr ppm kg/hr kg/hr f₂ %⁴ % Eff.⁵ 1253.6 31.4 354 4,470 120 600 0.49 5000 0.49 600 0.45 82.5 0.63 89.6 19.3281 13 38.6 32.4 288 2,303 ″ ″ 0.38 ″ 0.38 ″ 0.40 66.7 0.68 89.1 20.6303 14 62.1 18.8 425 4,768 ″ ″ 0.63 ″ 0.62 ″ 0.65 79.0 0.51 90.1 16.9202 15 65.5 13.4 345 3,951 130 ″ 0.86 ″ 0.85 ″ 0.44 73.4 0.34 92.2 19.0145 ¹standard cm³/min²[N-(2,6-di(1-methylethyl)phenyl)amido)(2-isopropylphenyl)(α-naphthalen-2-diyl(6-pyridin-2-diyl)methane)]hafniumdimethyl ³polymer production rate ⁴percent ethylene conversion inreactor ⁵efficiency, kg polymer/g M where g M = g Hf

TABLE 3 Density Mw Mn Ex. (g/cm³) I₂ I₁₀/I₂ (g/mol) (g/mol) Mw/Mn 120.8650 1.06 8.36 130 26.6 4.90 13 0.8560 0.92 8.00 142 49.6 2.87 140.8800 0.76 7.26 127 30.3 4.18 15 0.9030 0.97 7.00 107 24.3 4.40

The ethylene-octene copolymers in FIGS. 20-21 may be made in a similarmanner.

Examples 16-22 Comparative Polymers A-F

Comparative polymer A was AFFINITY® PL 1880G polymer obtained from TheDow Chemical Company, Midland, Mich. Comparative polymer B was ATTANE™4203 polymer obtained from The Dow Chemical Company. Comparative polymerC was EXACT™ 3132, which is an ethylene-based hexene plastomer obtainedfrom ExxonMobil Chemical, Houston, Tex. Comparative polymer D was aconventionally made ethylene-octene polymer. Comparative polymer E wasDow ATTANE™ 4201 G obtained from The Dow Chemical Company. Comparativepolymer F was EXCEED™ 1012 obtained from ExxonMobil Chemical.Comparative polymer G was a Ziegler-Natta Ethylene Octene Copolymerhaving a Melt Index of 0.5 and a density of 0.903 g/cc having thedesignation XUS 61520.15L obtained from The Dow Chemical Company.

Examples 16-22 were prepared in manner similar to the proceduredescribed for Examples 12-15 except that the process parameters of Table4 below were employed. The properties of the resulting polymers ofExamples 16-22 are shown in Tables 5 and 6 below.

TABLE 4 Diethyl Zinc Pre- Diethyl concen- Catalyst Pre- cat Zinc/tration Efficiency cat Al Cocat Cocat MMAO MMAO Ethylene in Poly (MM#C₂H₄ C₈H₁₆ Solv. H₂ T Al² Flow Conc. Flow Conc. Flow Ratio polymer Rat³Conv Solids Poly/ Ex. kg/hr Kg/hr kg/hr Sccm¹ (° C.) ppm Kg/hr ppm kg/hrppm kg/hr (1/1000) (ppm) kg/hr %⁴ % #Hf) 16 182 72.1 1056 16911 120.1500 1.59 6449 0.99 275 1.31 0.000 0 202 89.86 16.29 0.115 17 182 67.01056 7369 120.1 500 1.60 6449 1.08 275 1.32 0.142 125 199 89.90 16.070.113 18 206 99.2 1194 29974 120.0 600 1.11 6449 0.90 299 1.01 0.000 0201 79.64 14.38 0.136 19 206 99.2 1194 16323 120.1 500 1.58 6449 1.07299 1.20 0.127 125 200 79.74 14.29 0.115 20 195 47.5 1126 14939 125.1594 1.25 6449 0.93 299 1.13 0.000 0 202 89.98 15.29 0.123 21 195 43.51126 5510 125.1 559 1.24 6963 0.80 386 0.85 0.134 125 199 89.96 15.110.130 22 172 26.8 1208 6947 130.1 456 1.33 5752 0.85 541 1.02 0.000 0187 90.27 13.62 0.139 ¹standard cm³/min²[N-(2,6-di(1-methylethyl)phenyl)amido)(2-isopropylphenyl)(α-naphthalen-2-diyl(6-pyridin-2-diyl)methane)]hafniumdimethyl ³polymer production rate ⁴percent ethylene conversion inreactor

TABLE 5 Wt. % octene using Density Mw Mn Mw/ B matrix Ex. (g/cm3) I₂I₁₀/I₂ (g/mol) (g/mol) Mn value method 16 0.9022 0.94 6.35 106400 286703.71 1.03 16.54 17 0.9020 0.95 5.66 106100 43920 2.42 1.03 15.57 180.9029 0.93 5.86 108300 31580 3.43 19 0.9023 0.97 5.63 105000 45900 2.2920 0.9125 0.93 6.16 107700 30120 3.58 1.02 10.73 21 0.9117 0.93 5.59105200 43560 2.42 1.02 9.76 22 0.9059 0.44 6.53 125500 37300 3.36 1.02413.95

The Differential Scanning Calorimetry (DSC) curves of Examples 16-21 andComparative Examples A-F were measured according to the procedure below.A TA Instruments model Q1000 DSC equipped with an RCS cooling accessoryand an autosampler was used. A nitrogen purge gas flow of 50 ml/minutewas used. The sample was pressed and melted in a press at about 175° C.and then air-cooled to room temperature (25° C.) to form a thin film. Adisk of about 4-8 mg and 6 mm in diameter was cut from the thin film,accurately weighed, placed in a light aluminum pan (ca 50 mg), and thencrimped shut. Thermal behavior of the sample was investigated with thefollowing temperature profile. The sample was rapidly heated to 180° C.and held isothermal for 3 minutes in order to remove any previousthermal history. The sample was then cooled to −40° C. at 10° C./minutecooling rate and held at −40° C. for 3 minutes. The sample was thenheated to 190° C. at 10° C./minute heating rate. The area under themelting curve was measured from −20° C. to the end of the melting. TheDSC curves of Examples 16, 17, 20, and 21 are shown in FIGS. 22, 23, 24and 25 respectively. The DSC curve of Example 22 is shown in FIG. 28.The melting peak temperature is chosen as the temperature at the maximumin heat flow with respect to a linear baseline. For example, the meltingpeak temperature for Example 17 shown in FIG. 23 is 99.28° C., not122.07° C. The melting peak temperatures are reported in Table 6 below.The area under the DSC curve from the melting peak temperature to theend of the melting is reported as the melting peak residual area.Similarly, the enthalpy corresponding to the melting peak residual areais the residual enthalpy at melting peak. The melting peak residual areaas a percentage of the total enthalpy or heat of fusion is alsoreported. The DSC results are listed in Table 6 below.

TABLE 6 Residual Melting Melting Enthalpy Total Peak Peak at meltingEnthalpy Residual Samples (° C.) peak (J/g) (J/gm) Area (%) Example 1690.64 37.66 106 35.53 Example 17 99.28 19.48 102.8 18.95 Example 1893.01 35.72 107 33.38 Example 19 99.85 19.26 105 18.34 Example 20 108.4522.46 127.9 17.56 Example 21 108.43 22.92 127.3 18.00 Example 22 91.7319.79 88.35 22.40 Comparative 1st run 100.17 14.60 106.7 13.68 Polymer A2nd run 100.02 14.53 104.9 Comparative Polymer B 123.01 5.95 113.3 5.25Comparative Polymer C 95.42 16.60 103.8 15.99 Comparative Polymer D109.77 14.43 130.6 11.05 Comparative Polymer E 121.87 5.816 125.6 4.63Comparative Polymer F 114.84 12.77 128.5 9.94 Comparative Polymer G122.04 5.69 112.4 5.06

Two DSC curves for Comparative Polymer A were run using different DSCinstruments. FIGS. 26 and 27 show DSC curves of Comparative Polymer Aobtained using a TA Instruments model Q1000 DSC and a TA Instrumentsmodel 2920 DSC respectively. The DSC curves of Examples 16 and 17 arebimodal and broader than that of Comparative Polymer A.

Long Chain Branching (LCB)

The LCB results shown in Table 7 may be obtained using the techniquesdescribed in, for example, Randall (Rev. Macromol. Chem. Phys., C29(2&3), p. 285-297), the disclosure of which is incorporated herein byreference, or the techniques described by A. Willem deGroot and P. SteveChum Oct. 4, 1994 conference of the Federation of Analytical Chemistryand Spectroscopy Society (FACSS) in St. Louis, Mo., U.S.A., thedisclosure of which is incorporated herein by reference.

TABLE 7 Example LCB in 1000 carbon atoms 16 <0.01 17 <0.01 18 <0.01 19<0.01 20 <0.01 21 <0.01 22 <0.01Multilayer Film

The inventive interpolymers disclosed herein can be used in anymultilayer film known to a skilled artisan. In some embodiments, themultilayer film comprises a base layer and a sealant layer. In otherembodiments, the multilayer film comprises a base layer, a sealantlayer, and a tie layer between the base layer and the sealant layer.

In some embodiments, the base layer is a heat resistant layer having amelting point higher than that of the sealant layer. The heat resistantlayer can comprise a single polymer or a blend of two or more polymers.Some non-limiting examples of suitable polymers for the heat resistantlayer include polyethylene, polypropylene, polybutadiene, polystyrene,polyesters, polycarbonates, polyamides and combinations thereof. Anyother polymer that has a melting point higher than that of the sealantlayer disclosed herein can also be used. In a further embodiment, thebase layer comprises a polyamide.

In certain embodiments, the base layer is a non-heat resistant layerhaving a melting point lower than that of the sealant layer. Thenon-heat resistant layer can comprise a single polymer or a blend of twomore polymers. Some non-limiting examples of suitable polymers for thenon-heat resistant layer include low-density polyethylene,polypropylene, poly(3-hydroxybutyrate) (PHB), polydimethylsiloxane andcombinations thereof. Any other polymer that has a melting point lowerthan that of the sealant layer disclosed herein can also be used. Infurther embodiments, the base layer has about the same melting point asthe sealant layer and comprises any of the polymers mentioned above or acombination thereof.

In some embodiments, the thickness of the base layer can be from about1% to about 90%, from about 3% to about 80%, from about 5% to about 70%,from about 10% to about 60%, from about 15% to about 50%, or from about20% to about 40% of the total thickness of the multilayer film. In otherembodiments, the thickness of the base layer is from about 10% to about40%, from about 15% to about 35%, from about 20% to about 30%, or fromabout 22.5% to about 27.5% of the total thickness of the multilayerfilm. In further embodiments, the total thickness of the base layer isabout 25% of the total thickness of the multilayer film.

The sealant layer may comprise at least an ethylene/α-olefininterpolymer disclosed herein. In some embodiments, the sealant layermay further comprise one or more polymers comprising repeating unitsderived from ethylene, for example, low density polyethylene, otherethylene/α-olefin copolymers, ethylene/vinyl acetate copolymers,ethylene/alkyl acrylate copolymers, ethylene/acrylic acid copolymers, aswell as the metal salts of ethylene/acrylic acid, commonly referred toas inomers.

In some embodiments, the thickness of the sealant layer is from about 1%to about 90%, from about 3% to about 80%, from about 5% to about 70%,from about 10% to about 60%, from about 15% to about 50%, or from about20% to about 40% of the total thickness of multilayer film. In otherembodiments, the thickness of the sealant layer is from about 10% toabout 40%, from about 15% to about 35%, from about 20% to about 30%, orfrom about 22.5% to about 27.5% of the total thickness of the multilayerfilm. In further embodiments, the total thickness of the sealant layeris about 25% of the total thickness of the multi layer film.

The tie layer can be any layer that can promote the adhesion between itstwo adjacent layers. In some embodiments, the tie layer is between oradjacent to the base layer and the sealant layer. Some non-limitingexamples of suitable polymers for the tie layer include ethylene/vinylacetate copolymers, ethylene/methyl acrylate copolymers, ethylene/butylacrylate copolymers, very low density polyethylene (VLDPE), ultralowdensity polyethylene (ULDPE), TAFMER™ resins, as well as metallocenecatalyzed ethylene/α-olefin copolymers of lower densities. Generally,some resins suitable for use in the sealant layer can serve as tie layerresins. In some embodiments, the thickness of the sealant layer is fromabout 1% to about 99%, from about 10% to about 90%, from about 20% toabout 80%, from about 30% to about 70%, or from about 40% to about 60%of the total thickness of multilayer film. In other embodiments, thethickness of the sealant layer is from about 45% to about 55% of thetotal thickness of the multilayer film. In further embodiments, thetotal thickness of the sealant layer is about 50% of the total thicknessof the multilayer film.

In some embodiments, the multilayer film comprises at least two layers.For example, the multilayer film may comprise 2, 3, 4, 5, 6, 7, 8, 9,10, 11, 12, 13, 14, 15 or more layers of films.

Optionally, each layer of the multilayer film, such as the base layer,tie layer and sealant layer, may independently comprise or besubstantially free of at least an additive. Some non-limiting example ofsuitable additive include plasticizers, oils, waxes, antioxidants, UVstabilizers, colorants or pigments, fillers, flow aids, coupling agents,crosslinking agents, surfactants, solvents, slip agents, anti-blockingagents, lubricants, antifogging agents, nucleating agents, flameretardants, antistatic agents and combinations thereof. The total amountof the additives can range from about greater than 0 to about 80%, fromabout 0.001% to about 70%, from about 0.01% to about 60%, from about0.1% to about 50%, from about 1% to about 40%, or from about 10% toabout 50% of the total weight of the multilayer film. Some polymeradditives have been described in Zweifel Hans et al., “PlasticsAdditives Handbook,” Hanser Gardner Publications, Cincinnati, Ohio, 5thedition (2001), which is incorporated herein by reference in itsentirety. In some embodiments, the multilayer films disclosed herein donot comprise an additive such as those disclosed herein.

In some embodiments, one or more layers of the multilayer filmoptionally comprise a slip agent. Slip is the sliding of film surfacesover each other or over some other substrates. The slip performance offilms can be measured by ASTM D 1894, Static and Kinetic Coefficients ofFriction of Plastic Film and Sheeting, which is incorporated herein byreference. In general, the slip agent can convey slip properties bymodifying the surface properties of films; and reducing the frictionbetween layers of the films and between the films and other surfaceswith which they come into contact.

Any slip agent known to a person of ordinary skill in the art may beadded to at least an outer layer of the multilayer film disclosedherein. Non-limiting examples of the slip agents include primary amideshaving about 12 to about 40 carbon atoms (e.g., erucamide, oleamide,stearamide and behenamide); secondary amides having about 18 to about 80carbon atoms (e.g., stearyl erucamide, behenyl erucamide, methylerucamide and ethyl erucamide); secondary-bis-amides having about 18 toabout 80 carbon atoms (e.g., ethylene-bis-stearamide andethylene-bis-oleamide); and combinations thereof.

Optionally, one or more layers of the multilayer film disclosed hereincan comprise an anti-blocking agent. In some embodiments, the multilayerfilm disclosed herein do not comprise an anti-blocking agent. Theanti-blocking agent can be used to prevent the undesirable adhesionbetween touching layers of the multilayer film, particularly undermoderate pressure and heat during storage, manufacture or use. Anyanti-blocking agent known to a person of ordinary skill in the art maybe added to the multilayer film disclosed herein. Non-limiting examplesof anti-blocking agents include minerals (e.g., clays, chalk, andcalcium carbonate), synthetic silica gel (e.g., SYLOBLOC® from GraceDavison, Columbia, Md.), natural silica (e.g., SUPER FLOSS® from CeliteCorporation, Santa Barbara, Calif.), talc (e.g., OPTIBLOC® from Luzenac,Centennial, Colo.), zeolites (e.g., SIPERNAT® from Degussa, Parsippany,N.J.), aluminosilicates (e.g., SILTON® from Mizusawa IndustrialChemicals, Tokyo, Japan), limestone (e.g., CARBOREX® from Omya, Atlanta,Ga.), spherical polymeric particles (e.g., EPOSTAR®, poly(methylmethacrylate) particles from Nippon Shokubai, Tokyo, Japan andTOSPEARL®, silicone particles from GE Silicones, Wilton, Conn.), waxes,amides (e.g. erucamide, oleamide, stearamide, behenamide,ethylene-bis-stearamide, ethylene-bis-oleamide, stearyl erucamide andother slip agents), molecular sieves, and combinations thereof. Themineral particles can lower blocking by creating a physical gap betweenarticles, while the organic anti-blocking agents can migrate to thesurface to limit surface adhesion. Where used, the amount of theanti-blocking agent in the multilayer film can be from about greaterthan 0 to about 3 wt %, from about 0.0001 to about 2 wt %, from about0.001 to about 1 wt %, or from about 0.001 to about 0.5 wt % of thetotal weight of the multilayer film. Some anti-blocking agents have beendescribed in Zweifel Hans et al., “Plastics Additives Handbook,” HanserGardner Publications, Cincinnati, Ohio, 5th edition, Chapter 7, pages585-600 (2001), which is incorporated herein by reference.

Optionally, one or more layers of the multilayer film disclosed hereincan comprise a plasticizer. In general, a plasticizer is a chemical thatcan increase the flexibility and lower the glass transition temperatureof polymers. Any plasticizer known to a person of ordinary skill in theart may be added to the multilayer film disclosed herein. Non-limitingexamples of plasticizers include mineral oils, abietates, adipates,alkyl sulfonates, azelates, benzoates, chlorinated paraffins, citrates,epoxides, glycol ethers and their esters, glutarates, hydrocarbon oils,isobutyrates, oleates, pentaerythritol derivatives, phosphates,phthalates, esters, polybutenes, ricinoleates, sebacates, sulfonamides,tri- and pyromellitates, biphenyl derivatives, stearates, difurandiesters, fluorine-containing plasticizers, hydroxybenzoic acid esters,isocyanate adducts, multi-ring aromatic compounds, natural productderivatives, nitriles, siloxane-based plasticizers, tar-based products,thioeters and combinations thereof. Where used, the amount of theplasticizer in the multilayer film can be from greater than 0 to about15 wt %, from about 0.5 to about 10 wt %, or from about 1 to about 5 wt% of the total weight of the multilayer film. Some plasticizers havebeen described in George Wypych, “Handbook of Plasticizers,” ChemTecPublishing, Toronto-Scarborough, Ontario (2004), which is incorporatedherein by reference.

In some embodiments, one or more layers of the multilayer filmoptionally comprise an antioxidant that can prevent the oxidation ofpolymer components and organic additives in the multilayer film. Anyantioxidant known to a person of ordinary skill in the art may be addedto the multilayer film disclosed herein. Non-limiting examples ofsuitable antioxidants include aromatic or hindered amines such as alkyldiphenylamines, phenyl-α-naphthylamine, alkyl or aralkyl substitutedphenyl-α-naphthylamine, alkylated p-phenylene diamines,tetramethyl-diaminodiphenylamine and the like (e.g. CHIMASSORB 2020);phenols such as 2,6-di-t-butyl-4-methylphenol;1,3,5-trimethyl-2,4,6-tris(3′,5′-di-t-butyl-4′-hydroxybenzyl)benzene;tetrakis[(methylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)]methane(e.g., IRGANOX™ 1010, from Ciba Geigy, New York); acryloyl modifiedphenols; octadecyl-3,5-di-t-butyl-4-hydroxycinnamate (e.g., IRGANOX™1076, commercially available from Ciba Geigy); phosphites andphosphonites; hydroxylamines; benzofuranone derivatives; andcombinations thereof. Where used, the amount of the antioxidant in themultilayer film can be from about greater than 0 to about 5 wt %, fromabout 0.0001 to about 2.5 wt %, from about 0.001 to about 1 wt %, orfrom about 0.001 to about 0.5 wt % of the total weight of the multilayerfilm. Some antioxidants have been described in Zweifel Hans et al.,“Plastics Additives Handbook,” Hanser Gardner Publications, Cincinnati,Ohio, 5th edition, Chapter 1, pages 1-140 (2001), which is incorporatedherein by reference.

In other embodiments, one or more layers of the multilayer filmdisclosed herein optionally comprise an UV stabilizer that may preventor reduce the degradation of the multilayer film by UV radiations. AnyUV stabilizer known to a person of ordinary skill in the art may beadded to the multilayer film disclosed herein. Non-limiting examples ofsuitable UV stabilizers include benzophenones, benzotriazoles, arylesters, oxanilides, acrylic esters, formamidines, carbon black, hinderedamines, nickel quenchers, hindered amines, phenolic antioxidants,metallic salts, zinc compounds and combinations thereof. Where used, theamount of the UV stabilizer in the multilayer film can be from aboutgreater than 0 to about 5 wt %, from about 0.01 to about 3 wt %, fromabout 0.1 to about 2 wt %, or from about 0.1 to about 1 wt % of thetotal weight of the multilayer film. Some UV stabilizers have beendescribed in Zweifel Hans et al., “Plastics Additives Handbook,” HanserGardner Publications, Cincinnati, Ohio, 5th edition, Chapter 2, pages141-426 (2001), which is incorporated herein by reference.

In further embodiments, one or more layers of the multilayer filmdisclosed herein optionally comprise a colorant or pigment that canchange the look of the multilayer film to human eyes. Any colorant orpigment known to a person of ordinary skill in the art may be added tothe multilayer film disclosed herein. Non-limiting examples of suitablecolorants or pigments include inorganic pigments such as metal oxidessuch as iron oxide, zinc oxide, and titanium dioxide, mixed metaloxides, carbon black, organic pigments such as anthraquinones,anthanthrones, azo and monoazo compounds, arylamides, benzimidazolones,BONA lakes, diketopyrrolo-pyrroles, dioxazines, disazo compounds,diarylide compounds, flavanthrones, indanthrones, isoindolinones,isoindolines, metal complexes, monoazo salts, naphthols, b-naphthols,naphthol AS, naphthol lakes, perylenes, perinones, phthalocyanines,pyranthrones, quinacridones, and quinophthalones, and combinationsthereof. Where used, the amount of the colorant or pigment in themultilayer film can be from about greater than 0 to about 10 wt %, fromabout 0.1 to about 5 wt %, or from about 0.25 to about 2 wt % of thetotal weight of the multilayer film. Some colorants have been describedin Zweifel Hans et al., “Plastics Additives Handbook,” Hanser GardnerPublications, Cincinnati, Ohio, 5th edition, Chapter 15, pages 813-882(2001), which is incorporated herein by reference.

Optionally, one or more layers of the multilayer film disclosed hereincan comprise a filler which can be used to adjust, inter alia, volume,weight, costs, and/or technical performance. Any filler known to aperson of ordinary skill in the art may be added to the multilayer filmdisclosed herein. Non-limiting examples of suitable fillers includetalc, calcium carbonate, chalk, calcium sulfate, clay, kaolin, silica,glass, fumed silica, mica, wollastonite, feldspar, aluminum silicate,calcium silicate, alumina, hydrated alumina such as alumina trihydrate,glass microsphere, ceramic microsphere, thermoplastic microsphere,barite, wood flour, glass fibers, carbon fibers, marble dust, cementdust, magnesium oxide, magnesium hydroxide, antimony oxide, zinc oxide,barium sulfate, titanium dioxide, titanates and combinations thereof. Insome embodiments, the filler is barium sulfate, talc, calcium carbonate,silica, glass, glass fiber, alumina, titanium dioxide, or a mixturethereof. In other embodiments, the filler is talc, calcium carbonate,barium sulfate, glass fiber or a mixture thereof. Where used, the amountof the filler in the multilayer film can be from about greater than 0 toabout 80 wt %, from about 0.1 to about 60 wt %, from about 0.5 to about40 wt %, from about 1 to about 30 wt %, or from about 10 to about 40 wt% of the total weight of the multilayer film. Some fillers have beendisclosed in U.S. Pat. No. 6,103,803 and Zweifel Hans et al., “PlasticsAdditives Handbook,” Hanser Gardner Publications, Cincinnati, Ohio, 5thedition, Chapter 17, pages 901-948 (2001), both of which areincorporated herein by reference.

Optionally, one or more layers of the multilayer film disclosed hereincan comprise a lubricant. In general, the lubricant can be used, interalia, to modify the rheology of the molten multilayer film, to improvethe surface finish of molded articles, and/or to facilitate thedispersion of fillers or pigments. Any lubricant known to a person ofordinary skill in the art may be added to the multilayer film disclosedherein. Non-limiting examples of suitable lubricants include fattyalcohols and their dicarboxylic acid esters, fatty acid esters ofshort-chain alcohols, fatty acids, fatty acid amides, metal soaps,oligomeric fatty acid esters, fatty acid esters of long-chain alcohols,montan waxes, polyethylene waxes, polypropylene waxes, natural andsynthetic paraffin waxes, fluoropolymers and combinations thereof. Whereused, the amount of the lubricant in the multilayer film can be fromabout greater than 0 to about 5 wt %, from about 0.1 to about 4 wt %, orfrom about 0.1 to about 3 wt % of the total weight of the multilayerfilm. Some suitable lubricants have been disclosed in Zweifel Hans etal., “Plastics Additives Handbook,” Hanser Gardner Publications,Cincinnati, Ohio, 5th edition, Chapter 5, pages 511-552 (2001), both ofwhich are incorporated herein by reference.

Optionally, one or more layers of the multilayer film disclosed hereincan comprise an antistatic agent. Generally, the antistatic agent canincrease the conductivity of the multilayer film and to prevent staticcharge accumulation. Any antistatic agent known to a person of ordinaryskill in the art may be added to the multilayer film disclosed herein.Non-limiting examples of suitable antistatic agents include conductivefillers (e.g., carbon black, metal particles and other conductiveparticles), fatty acid esters (e.g., glycerol monostearate), ethoxylatedalkylamines, diethanolamides, ethoxylated alcohols, alkylsulfonates,alkylphosphates, quaternary ammonium salts, alkylbetaines andcombinations thereof. Where used, the amount of the antistatic agent inthe multilayer film can be from about greater than 0 to about 5 wt %,from about 0.01 to about 3 wt %, or from about 0.1 to about 2 wt % ofthe total weight of the multilayer film. Some suitable antistatic agentshave been disclosed in Zweifel Hans et al., “Plastics AdditivesHandbook,” Hanser Gardner Publications, Cincinnati, Ohio, 5th edition,Chapter 10, pages 627-646 (2001), both of which are incorporated hereinby reference.

In further embodiments, one or more layers of the multilayer filmdisclosed herein optionally comprise a cross-linking agent that can beused to increase the cross-linking density of the multilayer film. Anycross-linking agent known to a person of ordinary skill in the art maybe added to the multilayer film disclosed herein. Non-limiting examplesof suitable cross-linking agents include organic peroxides (e.g., alkylperoxides, aryl peroxides, peroxyesters, peroxycarbonates,diacylperoxides, peroxyketals, and cyclic peroxides) and silanes (e.g.,vinyltrimethoxysilane, vinyltriethoxysilane,vinyltris(2-methoxyethoxy)silane, vinyltriacetoxysilane,vinylmethyldimethoxysilane, and3-methacryloyloxypropyltrimethoxysilane). Where used, the amount of thecross-linking agent in the multilayer film can be from about greaterthan 0 to about 20 wt %, from about 0.1 to about 15 wt %, or from about1 to about 10 wt % of the total weight of the multilayer film. Somesuitable cross-linking agents have been disclosed in Zweifel Hans etal., “Plastics Additives Handbook,” Hanser Gardner Publications,Cincinnati, Ohio, 5th edition, Chapter 14, pages 725-812 (2001), both ofwhich are incorporated herein by reference.

In certain embodiments, one or more layers of the multilayer filmoptionally comprise a wax, such as a petroleum wax, a low molecularweight polyethylene or polypropylene, a synthetic wax, a polyolefin wax,a beeswax, a vegetable wax, a soy wax, a palm wax, a candle wax or anethylene/α-olefin interpolymer having a melting point of greater than25° C. In certain embodiments, the wax is a low molecular weightpolyethylene or polypropylene having a number average molecular weightof about 400 to about 6,000 g/mole. The wax can be present in the rangefrom about 10% to about 50% or 20% to about 40% by weight of the totalcomposition.

The ethylene/α-olefin interpolymer disclosed herein can be used toprepare the multilayer films by any known film processes. In someembodiments, the ethylene/α-olefin interpolymer is used in the sealantlayers of the multilayer films. Some non-limiting example of suitablefilm processes include blown film extrusion, cast film process, and thelaminate film process.

Blown Film Extrusion Process

In general, extrusion is a process by which a polymer is propelledcontinuously along a screw through regions of high temperature andpressure where it is melted and compacted, and finally forced through adie. The extruder can be a single screw extruder, a multiple screwextruder, a disk extruder or a ram extruder. Several types of screw canbe used. For example, a single-flighted screw, double-flighted screw,triple-flighted screw, or other multi-flighted screw can be used. Thedie can be a film die, blown film die, sheet die, pipe die, tubing dieor profile extrusion die. In a blown film extrusion process, a blownfilm die for monolayer or multilayer film can be used. The extrusion ofpolymers has been described in C. Rauwendaal, “Polymer Extrusion”,Hanser Publishers, New York, N.Y. (1986); and M. J. Stevens, “ExtruderPrincipals and Operation,” Ellsevier Applied Science Publishers, NewYork, N.Y., (1985), both of which are incorporated herein by referencein their entirety.

In a blown film extrusion process, one or more polymers can be first fedinto a heated barrel containing a rotating screw through a hopper, andconveyed forward by the rotating screw and melted by both friction andheat generated by the rotation of the screw. The polymer melt can travelthrough the barrel from the hopper end to the other end of the barrelconnected with a blown film die. Generally, an adapter may be installedat the end of the barrel to provide a transition between the blown filmdie and the barrel before the polymer melt is extruded through the slitof the blown film die. To produce multilayer films, an equipment withmultiple extruders joined with a common blown film die can be used. Eachextruder is responsible for producing one component layer, in which thepolymer of each layer can be melted in the respective barrel andextruded through the slit of the blown film die. After forced throughthe blown film die, the extrudate can be blown up by air from the centerof the blown film die like a balloon tube. Mounted on top of the die, ahigh-speed air ring can blow air onto the hot film to cool it. Thecooled film tube can then pass through nip rolls where the film tube canbe flattened to form a flat film. The flat film can be then either keptas such or the edges of the lay-flat can be slit off to produce two flatfilm sheets and wound up onto reels for further use. The volume of airinside the tube, the speed of the nip rollers and the extruders outputrate generally play a role in determining the thickness and size of thefilm.

In some embodiments, the barrel has a diameter of about 1 inch to about10 inches, from about 2 inches to about 8 inches, from about 3 inches toabout 7 inches, from about 4 inches to about 6 inches, or about 5inches. In other embodiments, the barrel has a diameter from about 1inch to about 4 inches, from about 2 inches to about 3 inches or about2.5 inches. In certain embodiments, the barrel has a length to diameter(L/D) ratio from about 10:1 to about 30:1, from about 15:1 to about25:1, or from about 20:1 to about 25:1. In further embodiments, the L/Dratio is from about 22:1 to about 26:1, or from about 24:1 to about25:1.

The barrel can be divided into several temperature zones. The zone thatis closest to the hopper end of the barrel is usually referred to asZone 1. The zone number increases sequentially towards the other end ofthe barrel. In some embodiments, there are 1, 2, 3, 4, 5, 6, 7, 8, 9, or10 temperature zones in a barrel. In other embodiments, there are morethan 10, more than 15, more than 20 temperature zones in a barrel. Thetemperature of each temperature zone in the barrel can range from about50° F. to about 1000° F., from about 80° F. to about 800° F., from about100° F. to about 700° F. from about 150° F. to about 600° F., from about200° F. to about 500° F., or from about 250° F. to about 450° F. In someembodiments, the barrel temperature increases sequentially from thefirst Zone to the last Zone. In other embodiments, the barreltemperature remains substantially the same throughout the barrel. Inother embodiments, the barrel temperature decreases from the first Zoneto the last Zone. In further embodiments, the barrel temperature changesrandomly from one zone to another.

In some embodiments, the die can also be heated to a specifictemperature, ranging from about 250° F. to about 700° F., from about300° F. to about 600° F., from about 350° F. to about 550° F., fromabout 400° F. to about 500° F. In other embodiments, the die temperatureranges from about 425° F. to about 475° F. or from 430° F. to about 450°F.

The adapter temperature can be between the die temperature and thetemperature of the last zone. In some embodiments, the adaptertemperature is from about 200° F. to about 650° F., from about 250° F.to about 600° F., from about 300° F. to about 550° F., from about 350°F. to about 500° F., and from about 400° F. to about 450° F.

Cast Film Process

The cast film process involves the extrusion of polymers melted througha slot or flat die to form a thin, molten sheet or film. This film canthen be “pinned” to the surface of a chill roll by a blast of air froman air knife or vacuum box. The chill roll can be water-cooled andchrome-plated. The film generally quenches immediately on the chill rolland can subsequently have its edges slit prior to winding.

Because of the fast quench capabilities, a cast film generally is moreglassy and therefore has a higher optic transmission than a blown film.Further, cast films generally can be produced at higher line speeds thanblown films. Further, the cast film process may produce higher scrap dueto edge-trim, and may provide films with very little film orientation inthe cross-direction.

As in blown film, co-extrusion can be used to provide multilayer filmsdisclosed herein. In some embodiments, the multilayer films may haveadditional functional, protective, and decorative properties thanmonolayer films. Cast films can be used in a variety of markets andapplications, including stretch/cling films, personal care films, bakeryfilms, and high clarity films.

In some embodiments, a cast film line may comprise an extrusion system,a casting machine, and a winder. Optionally, the cast film line mayfurther comprise a gauging system, a surface treatment system and/or anoscillation stand. The cast film die can be generally positionedvertically above the main casting roll and the melt can be pinnedagainst the casting roll with the use of an air knife and/or vacuum box.

The casting machine is generally designed to cool the film and providethe desired surface finish on the film. In some embodiments, the castingmachine comprises two casting rolls. The main casting roll may be usedto provide initial cooling and surface finish on the film. The secondarycasting roll can cool the opposite side of the film to provideuniformity in the film. For embossed film applications, the casting rollmay have an engraved pattern and can be nipped with a rubber roll.Optionally, a water bath and squeegee roll can be used for cooling thesurface of the rubber roll.

The casting rolls can be double shell style with spiral baffle, and mayhave an internal flow design to maintain superior temperature uniformityacross the width of the web. Optionally, cold water from the heattransfer system can be circulated to cool the rolls.

Once cast, the film can optionally pass through a gauging system tomeasure and control thickness. Optionally, the film can besurface-treated either by a corona or a flame treater and passed throughan oscillating station to randomize any gauge bands in the final woundproduct. Before the cast film enters the winder, the edges can betrimmed for recycling or disposal. In some embodiments, automatic rolland shaft handling equipment are sometimes provided for winders withshort cycle times.

Laminate Film Process

In the laminate film process for making a multilayer film, the polymersfor each of the layers are independently processed by an extruder topolymer melts. Subsequently, the polymer melts are combined in layers ina die, formed into a casting, and quenched to the solid state. Thiscasting may be drawn uniaxially in the machine direction by reheating tofrom about 50° C. to about 200° C. and stretching from about 3 times toabout 10 times between rolls turning at different speeds. The resultinguniaxially oriented film can then be oriented in the transversedirection by heating to from about 75° C. to about 175° C. in an airheated oven and stretching from about 3 times to about 10 times betweendiverging clips in a tenter frame.

Alternately, the two direction stretching may take place simultaneouslyin which case the stretching may be from about 3 times to about 10 timesin each direction. The oriented film can be cooled to near ambienttemperature. Subsequent film operations, such as corona treatment andmetalization, may then be applied. Alternatively, the layers of themultilayer film can be brought together in stages rather than throughthe same die. In some embodiments, the base layer is cast initially, andthen the sealant layer can be extrusion coated onto the base layercasting. In other embodiments, the sealant layer is cast initially, andthen the base layer can be extrusion coated onto the sealant layercasting. In further embodiments, the sealant layer is cast initially,and then the tie layer and base layer can be extrusion coated onto thesealant layer casting sequentially or simultaneously. In furtherembodiments, the base layer is cast initially, and then the tie layerand sealant layer can be extrusion coated onto the base layer castingsequentially or simultaneously. This extrusion coating step may occurprior to MD orientation or after MD orientation.

If desirable, the multilayer film can be coated with a metal such asaluminum, copper, silver, or gold using conventional metalizingtechniques. The metal coating can be applied to the base layer orsealant layer by first corona treating the surface of the base layer orsealant layer and then applying the metal coating by any known methodsuch as sputtering, vacuum deposition, or electroplating.

If desirable, other layers may be added or extruded onto the multilayerfilm, such an adhesive or any other material depending on the particularend use. For example, the outer surface of the multilayer film, such asthe base layer or sealant layer, may be laminated to a layer ofcellulosic paper.

Three Layer Blown Film

Three-layer films were made by a blown film extrusion process on a 6inch 3-Layer co-extrusion blown film line. The equipment was as follows:

1. Extruder A 2½″ Egan 60 HP, 100 amp Max, 127 RPM, 24:1 Ratio.

2. Extruder B 2½″ Egan 75 HP, 123 amp Max, 157 RPM, 24:1 Ratio.

3. Extruder C 2″ Johnson 20 HP, 42 amp Max, 150 RPM, 24:1 Ratio.

4. Haul-Off, 500 fpm Max.

A Battenfeld Gloucester Extrol 6032 Process Control System with CRTdisplay screen and printer was employed with a Battenfeld Gloucesterhopper loading system with three hoppers. A six inch 3 layerco-extrusion Macro die and air ring was employed along with a die gap of70 mil. A 10 HP Buffalo blower with variable speed control for air ringcooling air was used in conjunction with piped in block chilled waterfor chilled air in air ring. Other equipment included a Gloucester towerwith Sano collapsing frame, bubble sizing cage and bubble enclosure for18 to 40 inch lay flat, with nip rolls 54″ long, adjustable bubble cageelevators, 15 HP blower on collapsing frame, a Gloucester 116 dualturret winder with 52″ lug type expanding shafts with automaticcut-over, a 200 CFM fan coil heat exchanger from AEC, a BattenfeldGloucester Internal Bubble Cooling (IBC) System, a Battenfeld GloucesterCooling System for the IBC System.

Two screws for the 2½″ Egan Extruders were used. The core is a DSB IImanufactered by Davis Standard, has a bar flight type, a metering depthof 0.204 inches, a feed depth of 0.48 inches, a comp. ratio of 2.35, aMAD mixer type, a 0.04 inch mixer clear, a feed length of 5 inches, atran. length of 14 inches and a meter length of 2 inches. The outsidescrew for the 2½″ Egan Extruder is a SF High shear (with 2interchangeable mixers) manufactured by New Castle, has an SF flighttype, a metering depth of 0.104 inches, a feed depth of 0.3 inches, acomp. ratio of 2.88, a twisted Egan/Z-mixer type, a 0.0345 mixer clear,a feed length of 6 inches, a tran. length of 6 inches and a meter lengthof 12 inches.

The screw for the 2″ Johnson Extruder is manufactered by Johnson, has anSF flight type, a metering depth of 0.17 inches, a feed depth of 0.425inches, a comp. ratio of 2.5, a MAD mixer type, a 0.035 inch mixerclear, a feed length of 5 inches, a tran. length of 8 inches and a meterlength of 8 inches.

Precision Air Convey Corporation Trim Removal System model numberBC3-06-22A and Western Polymers Entrac Dual Iris for 6 inch monolayerdie Model Number SAT II 0601 were also employed.

Three-layer films were made by a blown film extrusion process using theequipment above. One extruder was used for making the sealant layer,which has a barrel diameter of 2.5 inch and a single-flight-high-shearscrew with a screw compression ratio of 2.88. A second extruder was usedfor making the tie layer, which has a barrel diameter of 2.5 inch and amodified-double-mix screw with a screw compression ratio of 3.64. Athird extruder was used for making the base layer, which has a barreldiameter of 2.0 inch and a single-flighted screw with a screwcompression ratio of 2.5. Each barrel has a length to diameter (L/D)ratio of 24:1 and has four temperature Zones, i.e., Zone 1, Zone 2, Zone3, and Zone 4. Zone 1 is closest to the hopper end and Zone 4 is closestto the die end. The barrel diameter was 2.5 inch. All of barrels havesmooth surfaces. The chill roll temperature was about 15° C. The NipPressure was about 13 kg/cm. The Extrusion Rate was about 35 kg/hr.

The temperatures profiles of each extruder is listed in Table 8 below.

TABLE 8 Sealant Tie Base Film Layer layer layer layer Zone 1 (° F.) 285375 400 Zone 2 (° F.) 300 425 425 Zone 3 (° F.) 385 375 440 Zone 4 (°F.) 385 375 440 Adapter Temp. 410 400 440 (° F.)

According to the type of polymers used, the following films were made.

Example BB

Example BB comprised a sealant layer made of 100% polymer of Example 16,a tie layer made of 90% ATTANE™ 4201 G, a linear low densitypolyethylene (LLDPE) having an I₂ of 1 and a density of 0.912 g/ccavailable at Dow Chemical, 10% of AMPLIFY™ GR 205, a maleicanhydride-grafted polyethylene available at Dow Chemical, and a baselayer made of 100% ULTRAMID® C33L, a polyamide copolymer available atBASF. The total thickness of the film was 3.5 mils. The base layer had athickness of 0.875 mils, constituting 25% of the total thickness. Thetie layer had a thickness of 1.75 mils, constituting 50% of the totalthickness. The sealant layer had a thickness of 0.875, constituting 25%of the total thickness.

Example CC

Example CC comprised a sealant layer made of 100% polymer of Example 17,a tie layer made of 90% ATTANE™ 4201 G, a linear low densitypolyethylene (LLDPE) having an I₂ of 1 and a density of 0.912 g/ccavailable at Dow Chemical, 10% of AMPLIFY™ GR 205, a maleicanhydride-grafted polyethylene available at Dow Chemical, and a baselayer made of 100% ULTRAMID® C33L, a polyamide copolymer available atBASF. The total thickness of the film was 3.5 mils. The base layer had athickness of 0.875 mils, constituting 25% of the total thickness. Thetie layer had a thickness of 1.75 mils, constituting 50% of the totalthickness. The sealant layer had a thickness of 0.875, constituting 25%of the total thickness.

Comparative Example DD

Comparative Example DD comprised a sealant layer made of 100% AFFINITY™PL 1880G having an I₂ of 1 and a 0.902 g/cc density, a tie layer made of90% ATTANE™ 4201 G, a linear low density polyethylene (LLDPE) having anI₂ of 1 and a density of 0.912 g/cc available at Dow Chemical, 10% ofAMPLIFY™ GR 205, a maleic anhydride-grafted polyethylene available atDow Chemical, and a base layer made of 100% ULTRAMID® C33L, a polyamidecopolymer available at BASF. The total thickness of the film was 3.5mils. The base layer had a thickness of 0.875 mils, constituting 25% ofthe total thickness. The tie layer had a thickness of 1.75 mils,constituting 50% of the total thickness. The sealant layer had athickness of 0.875, constituting 25% of the total thickness.

Comparative Example EE

Comparative Example EE comprised a sealant layer made of 100% EXACT™3132 having an I₂ of 1.02 and 0.900 g/cc density, a tie layer made of90% ATTANE™ 4201G, a linear low density polyethylene (LLDPE) having anI₂ of 1 and a density of 0.912 g/cc available at Dow Chemical, 10% ofAMPLIFY™ GR 205, a maleic anhydride-grafted polyethylene available atDow Chemical, and a base layer made of 100% ULTRAMID® C33L, a polyamidecopolymer available at BASF. The total thickness of the film was 3.5mils. The base layer had a thickness of 0.875 mils, constituting 25% ofthe total thickness. The tie layer had a thickness of 1.75 mils,constituting 50% of the total thickness. The sealant layer had athickness of 0.875, constituting 25% of the total thickness.

Example II

Example II was a two-layer film. The base layer was made of BiaxiallyOriented Polypropylene (BOPP) with a thickness of 0.5 mils. The sealantlayer was made of the polymer of Example 18 with a thickness of 0.75mils.

Example JJ

Example JJ was a three-layer film. The inside base layer was made of PETor Nylon with a thickness of 2 mils. The outside sealant layer was madeof the polymer of Example 19 with a thickness of 2 mils. The tie layerbetween the sealant layer and the base layer was poly(ethylene vinylacetate) with a thickness of 1 mils.

Example KK

Example KK was a four-layer film. The first layer was a base layer madeof polycarbonates with a thickness of 0.1 mils. The second layer was atie layer made of low density polyethylene (LDPE) with a thickness of0.3 mils. The third layer was a sealant layer made of the polymer ofExample 20 with a thickness of 0.7 mils.

Example LL

Example LL was a five-layer film. The first layer was a base layer madeof polystyrene with a thickness of 0.3 mils. The second layer was a tielayer made of acid-modified polyolefin polymer with a thickness of 1mil. The third layer was a middle layer made of vinylidene chloride(VDC)-methyl acrylate (MA) copolymer with a thickness of 0.5 mils. Thefourth layer was a tie layer also made of acid-modified polyolefinpolymer with a thickness of 1 mil. The fifth layer was a sealant layermade of the polymer of Example 21 with a thickness of 1.8 mils.

For examples BB-EE, the extruder profiles are approximately the same asshown in Table 8. For Examples MM through PP below, the extruderprofiles are shown in Table 8a below:

TABLE 8a Sealant Tie Base Film Layer layer layer layer Zone 1 (° F.) 375375 400 Zone 2 (° F.) 425 425 425 Zone 3 (° F.) 375 375 440 Zone 4 (°F.) 375 375 440 Adapter Temp. 400 400 440 (° F.)

Example MM

Example MM comprised a sealant layer made of 100% polymer of Example 20,a tie layer made of 90% DOWLEX™ 2038.68G, having a 1 I2 and a 0.935 g/ccdensity, a linear low density polyethylene (LLDPE) available at DowChemical, 10% of AMPLIFY™ GR 205, a maleic anhydride-graftedpolyethylene available at Dow Chemical, and a base layer made of 100%ULTRAMID® C33L, a polyamide copolymer available at BASF. The totalthickness of the film was 3.5 mils. The base layer had a thickness of0.875 mils, constituting 25% of the total thickness. The tie layer had athickness of 1.75 mils, constituting 50% of the total thickness. Thesealant layer had a thickness of 0.875, constituting 25% of the totalthickness.

Example NN

Example NN comprised a sealant layer made of 100% polymer of Example 21,a tie layer made of 90% DOWLEX™ 2038.68G, a linear low densitypolyethylene (LLDPE) available at Dow Chemical, 10% of AMPLIFY™ GR 205,a maleic anhydride-grafted polyethylene available at Dow Chemical, and abase layer made of 100% ULTRAMID® C33L, a polyamide copolymer availableat BASF. The total thickness of the film was 3.5 mils. The base layerhad a thickness of 0.875 mils, constituting 25% of the total thickness.The tie layer had a thickness of 1.75 mils, constituting 50% of thetotal thickness. The sealant layer had a thickness of 0.875,constituting 25% of the total thickness.

Comparative Example OO

Comparative Example OO comprised a sealant layer made of 100% polymer ofATTANE™ 4201G, a tie layer made of 90% DOWLEX™ 2038.68G, a linear lowdensity polyethylene (LLDPE) available at Dow Chemical, 10% of AMPLIFY™GR 205, a maleic anhydride-grafted polyethylene available at DowChemical, and a base layer made of 100% ULTRAMID® C33L, a polyamidecopolymer available at BASF. The total thickness of the film was 3.5mils. The base layer had a thickness of 0.875 mils, constituting 25% ofthe total thickness. The tie layer had a thickness of 1.75 mils,constituting 50% of the total thickness. The sealant layer had athickness of 0.875, constituting 25% of the total thickness.

Comparative Example PP

Comparative Example PP comprised a sealant layer made of 100% polymer ofEXCEED™ 1012CA, a 1 I2, 0.912 g/cc density LLDPE available fromExxonMobil Corporation, a tie layer made of 90% DOWLEX™ 2038.68G, alinear low density polyethylene (LLDPE) available at Dow Chemical, 10%of AMPLIFY™ GR 205, a maleic anhydride-grafted polyethylene available atDow Chemical, and a base layer made of 100% ULTRAMID® C33L, a polyamidecopolymer available at BASF. The total thickness of the film was 3.5mils. The base layer had a thickness of 0.875 mils, constituting 25% ofthe total thickness. The tie layer had a thickness of 1.75 mils,constituting 50% of the total thickness. The sealant layer had athickness of 0.875, constituting 25% of the total thickness.

Hot Tack Strength

Hot tack strength of BB-PP was measured on a J&B type Hot Tack testingapparatus following ASTM F 1921, Method B. As the thickness of thesealant layer was less than 1 mil, the dwell time was 500 ms. The sealpressure was 27.5 N/cm². Test specimens were 1 inch in width and wereconditioned as specified by ASTM E 171. All specimens tested failed inan adhesive failure mode. The results are listed in Table 9 below.

TABLE 9 Seal Bar Temperature (° C.) Example 80 90 100 110 120 130 140150 160 Ex. No. of Specimen 5 5 7 6 5 7 6 5 7 BB Average Hot Tack 0.861.43 3.87 6.43 8.58 7.58 5.96 3.99 2.84 (N) Standard Deviation 0.39 0.590.61 0.55 0.35 0.69 0.60 0.32 0.49 (N) Ex. No. of Specimen 3 7 12 9 5 68 9 5 CC Average Hot Tack 0.25 1.78 6.51 11.94 11.49 10.94 7.81 4.990.07 (N) Standard Deviation 0.16 0.49 1.45 1.58 0.65 0.89 1.12 0.84 0.04(N) Ex. No. of Specimen 6 6 9 6 6 5 7 9 9 DD Average Hot Tack 3.12 4.266.18 6.20 6.50 5.54 4.80 4.09 3.38 (N) Standard Deviation 0.28 0.47 0.90.57 0.72 0.39 0.49 0.88 0.84 (N) Ex. No. of Specimen 5 5 12 6 6 10 10 814 EE Average Hot Tack 0.35 0.86 8.45 13.72 8.5 8.55 6.7 3.98 4.43 (N)Standard Deviation 0.22 0.81 1.52 0.67 0.54 1.12 1.21 0.75 2.18 (N) Ex.No. of Specimen 0 4 4 4 4 4 4 4 6 MM Average Hot Tack 0.08 2.01 6.639.08 9.98 8.64 6.97 4.14 (N) Standard Deviation 0.02 0.68 1.41 0.20 0.290.26 0.70 1.02 (N) Ex. No. of Specimen 0 4 3 4 4 4 4 4 4 NN Average HotTack 0.06 1.30 8.86 11.52 11.94 9.64 6.19 4.28 (N) Standard Deviation0.02 0.23 0.63 0.85 0.37 1.58 0.62 0.62 (N) Ex. No. of Specimen 4 4 4 44 4 4 4 4 OO Average Hot Tack 3.16 4.85 6.06 6.64 6.38 6.15 5.82 5.154.42 (N) Standard Deviation 1.31 0.48 0.38 0.18 0.33 0.25 1.46 0.87 0.62(N) Ex. No. of Specimen 4 4 4 4 4 4 4 4 6 PP Average Hot Tack 0.10 1.846.86 10.31 10.10 9.90 9.30 6.49 4.49 (N) Standard Deviation 0.04 0.631.19 0.55 1.48 0.42 1.48 1.11 1.44 (N)

The average hot tack force (N) of multilayer films of BB, CC, DD, and EEat different temperatures is shown in FIG. 30. It can be seen that BBand CC that comprises the inventive polymers have improved hot tackproperties over DD and EE that comprise comparative polymers. Theaverage hot tack force (N) of multilayer films of examples MM, NN, OO,and PP are shown in FIG. 31. It can also be seen that Example NN hasimproved hot tack properties over Example OO and PP.

Oriented Films

A 25 mil thick film was made using the ethylene/α-olefin interpolymer ofExample 22 and subsequently biaxially stretched using a Bruckner biaxialTenter frame labscale device approximately 4.5× in each direction for afilm gauge of about 1.25 mil. The film was oriented at varioustemperatures and the instrumented Dart impact was tested at ambienttemperature using 0.5 inch diameter dart size, a clamp diameterfilms/1.5 in clamp, and a speed of 3.4 m/s. The results for the orientedfilm comprising the interpolymer of example 22 is shown in Table 10. Theabove procedure was conducted again except that Comparative Polymer Gwas substituted for the polymer of Example 22. The results for theoriented film comprising the interpolymer of Comparative Polymer G isshown in Table 11.

TABLE 10 Oriented Film of Example 22 Orientation Temperature 97°C. 99°C. 102° C. Peak Defl 2.4 2.3 1.8 avg (in.) Peak Defl 0.1 0 0 sdv (in.)Peak energy 21.3 19.2 6.7 avg (inch-lbs) Peak Energy 4.3 1.4 1 sdv(inch-lbs) Peak load 56.5 54.5 35.6 avg (lbs) Peak load 7.3 3.9 3.1 sdv(lbs) Total energy 21.8 19.3 6.8 avg (inch-lbs) Total energy 4.2 1.4 1sdv (inch-lbs)

TABLE 11 Oriented Film of Comparative Polymer G Orientation Temperature91° C. 94° C. 98° C. 102° C. Peak Defl 2 2 1.9 1.9 avg (in.) Peak Defl 00 0 0 sdv (in.) Peak energy 15 13.3 11 9.6 avg (inch-lbs) Peak Energy1.2 2.2 1.8 1.3 sdv (inch-lbs) Peak load 52.6 47 39.9 33.8 avg (lbs)Peak load 1.1 1.6 2.1 1.6 sdv (lbs) Total energy 15.2 13.7 11.6 10 avg(inch-lbs) Total energy 1.5 1.9 1.8 1.3 sdv (inch-lbs)

A comparison of average peak load and average total energy is attachedas FIG. 32 for the film comprising Example 22 and the film comprisingComparative Polymer G.

Bi-Axially Oriented Multi-Layer Films

The first barrier layer—comprises a barrier polymer, particularly havingbarrier to oxygen. Suitable barrier polymer are Polyvinylidiene chloridecopolymer (e.g. Saran from the Dow chemical company), EVOH, Nylon, etc.

Adhesive layers—Adhesive layers each adhered to a respective one of theopposite surface of barrier layer. Suitable polymers for adhesive layersinclude EVA, MAH-g-Polyethylene, etc.

The multi-layer film is biaxially oriented below the melting point ofthe unique quasi-homogeneous polyethylene resins using double-bubble,trapped bubble or tenter frame processes well-known in the art. The filmcan be crosslinked via E-beam radiation or UV radiation prior to theorientation step or after the orientation step. The film has improvedpuncture and dart impact (toughness) properties while relativelymaintaining extrusion processing and ease of orientation in the secondbubble. Multi-layer films may be prepared according to the presentinvention using double bubble process according to, for example, U.S.Pat. No. 3,456,044. The film may be irradiated before or after theorientation step if desired. The below film examples may be madeaccording to the invention. Layer ratios and film thickness can bevaried to get desired barrier property and desired toughness (punctureand dart impact) properties.

Layer 1 ETHYLENE/A-OLEFIN INTERPOLYMER

Layer 2 Vinylidene chloride-methyl acrylate (VDC-MA) copolymer asBarrier polymer

Layer 3 Polyolefin

Layer 1 ETHYLENE/A-OLEFIN INTERPOLYMER

Layer 2 Adhesive layer

Layer 3 VDC-MA copolymer

Layer 4 adhesive layer comprising 12% VA EVA

Layer 5 ETHYLENE/A-OLEFIN INTERPOLYMER

Layer 1 ETHYLENE/A-OLEFIN INTERPOLYMER-EVA blend

Layer 2 Adhesive layer

Layer 3 VDC-MA copolymer

Layer 4 adhesive layer

Layer 5 ETHYLENE/A-OLEFIN INTERPOLYMER

Layer 1 ETHYLENE/A-OLEFIN INTERPOLYMER-EVA blend

Layer 2 Adhesive layer,

Layer 3 VDC-MA copolymer

Layer 4 adhesive layer

Layer 5 ETHYLENE/A-OLEFIN INTERPOLYMER-EVA (12% VA) 70/30 blend

Layer 1 Nylon 6

Layer 2 Adhesive layer

Layer 3 EVOH

Layer 4 adhesive layer

Layer 5 ETHYLENE/A-OLEFIN INTERPOLYMER

Layer 1 Nylon 6

Layer 2 Adhesive layer

Layer 3 70/30 EVOH/Nylon 6 blends

Layer 4 adhesive layer

Layer 5 ETHYLENE/A-OLEFIN INTERPOLYMER

Layer 1 ETHYLENE/A-OLEFIN INTERPOLYMER-VLDPE (0.905 g/cc, 0.8 MI) 70/30blend

Layer 2 Adhesive layer

Layer 3 VDC-MA copolymer

Layer 4 adhesive layer

Layer 5 ETHYLENE/A-OLEFIN INTERPOLYMER

Layer 1 ETHYLENE/A-OLEFIN INTERPOLYMER-VLDPE blend

Layer 2 Adhesive layer

Layer 3 VDC-MA copolymer

Layer 4 adhesive layer, 12% VA EVA

Layer 5 ETHYLENE/A-OLEFIN INTERPOLYMER-VLDPE blend

Layer 1 ETHYLENE/A-OLEFIN INTERPOLYMER-LLDPE blend

Layer 2 Adhesive layer, 12% VA EVA

Layer 3 VDC-MA copolymer

Layer 4 adhesive layer, 12% VA EVA

Layer 5 ETHYLENE/A-OLEFIN INTERPOLYMER

Layer 1 ETHYLENE/A-OLEFIN INTERPOLYMER-EVA blend

Layer 2 VDC-MA copolymer

Layer 3 ETHYLENE/A-OLEFIN INTERPOLYMER-EVA blend

Layer 1 ETHYLENE/A-OLEFIN INTERPOLYMER

Layer 2 Adhesive layer

Layer 3 EVOH

Layer 4 adhesive layer

Layer 5 ETHYLENE/A-OLEFIN INTERPOLYMER

Layer 1 ETHYLENE/A-OLEFIN INTERPOLYMER

Layer 2 Adhesive layer

Layer 3 EVOH-Nylon blends

Layer 4 adhesive layer

Layer 5 ETHYLENE/A-OLEFIN INTERPOLYMER

Layer 1 ETHYLENE/A-OLEFIN INTERPOLYMER

Layer 2 Adhesive layer

Layer 3 VDC-MA

Layer 4 adhesive layer

Layer 5 VLDPE

Layer 1 ETHYLENE/A-OLEFIN IN having 0.902 g/cc, MI=1.0, I10/12=5.6

Layer 2 Adhesive layer

Layer 3 PET or Nylon

Layer 1 ETHYLENE/A-OLEFIN INTERPOLYMER having 0.902 g/cc, MI=1.0,I10/12=5.6

Layer 2 Adhesive layer

Layer 3 VDC-MA copolymer

Layer 4 adhesive layer

Layer 5 Nylon

Layer 1 ETHYLENE/A-OLEFIN INTERPOLYMER having 0.902 g/cc, MI=1.0,I10/12=5.6

Layer 2 Adhesive layer

Layer 3 BOPP

Layer 1 ETHYLENE/A-OLEFIN INTERPOLYMER having 0.902 g/cc, MI=1.0,I10/12=5.6

Layer 2 LDPE

Layer 3 BOPP

Theoretical Methods and Explanation

To support the instant invention calculations were carried out using thecommercially-available software package, Gaussian98 Revision A.10distributed by Gaussian, Inc., Pittsburgh Pa., 2001. The computationsutilized the density functional theory (DFT) method, B3LYP as describedin, for example, Becke, A. D. J. Chem. Phys. 1993, 98, 5648; Lee, C.;Yang, W.; Parr, R. G. Phys. Rev B 1988, 37, 785; and Miehlich, B.;Savin, A.; Stoll, H.; Preuss, H. Chem. Phys. Lett. 1989, 157, 200 eachof which is incorporated herein by reference. In a few cases, theresults were reconfirmed using conventional theory with correlation,Møller-Plesset perturbation theory to second order (MP2) as describedin, for example, Møller, C.; Plesset, M. S. Phys. Rev. 1934, 46, 618;Head-Gordon, M.; Pople, J. A.; Frisch, M. J. Chem. Phys. Lett. 1988,153, 503; Frisch, M. J.; Head-Gordon, M.; Pople, J. A. Chem. Phys. Lett.1990, 166, 275; Frisch, M. J.; Head-Gordon, M.; Pople, J. A. Chem. Phys.Lett. 1990, 166, 281; Head-Gordon, M.; Head-Gordon, T. Chem. Phys. Lett.1994, 220, 122; and Saebo, S.; Almlof, J. Chem. Phys. Lett. 1989, 154,83 each of which is incorporated herein by reference. Qualitatively, theresults using MP2 were similar to those for B3LYP. A series of differentbasis sets were used and tested. Initially the modest LANL2DZ basis setas described in, for example, Dunning, Jr., T. H.; Hay, P. J. in ModernTheoretical Chemistry, Ed. H. F. Schaefer, III, Plenum, New York, 1976,vol 3, 1; Hay, P. J. Wadt, W. R. J. Chem. Phys. 1985, 82, 270; Wadt, W.R; Hay, P. J. J. Chem. Phys. 1985, 82, 284; and Hay, P. J. Wadt, W. R.J. Chem. Phys. 1985, 82, 299, was used for all atoms, but progressivelylarger basis sets were employed such as i) LANL2DZ on the transitionmetal and 6-31G* on all the other atoms as described in Ditchfield, R.;Hehre, W. J.; Pople, J. A. J. Chem. Phys. 1971, 54, 724; Hehre, W. J.;Ditchfield, R.; Pople, J. A. J. Chem. Phys. 1972, 56, 2257; and Gordon,M. S. Chem. Phys. Lett. 1980, 76, 163 and ii) LANL2DZ on the transitionmetal and 6-311G** on all other atoms as described in McLean, A. D.;Chandler, G. S. J. Chem. Phys. 1980, 72, 5639; and Krishnan, R.;Binkley, J. S.; Seeger, R.; Pople, J. A. J. Chem. Phys. 1980, 72, 650and these did not qualitatively change the results. The inclusion ofenthalpic and free energy corrections at a given temperature also didnot change the results significantly.

The calculations involved locating four stationary points on thepotential energy surface (see Diagram 1). Standard optimizations anddefaults within the Gaussian98 program were utilized which included theBerny optimizer in redundant internal coordinates as described in Peng,C.; Ayala, P. Y.; Schlegel, H. B. Frisch, M. J. J. Comp. Chem. 1996, 17,49; and Peng, C.; Schlegel, H. B. Israel. J. Chem. 1994, 33, 449. Thefour structures located were the transition state for ethylene insertinginto the M-aryl or M-hydrocarbyl bond of the original species (1), thetransition state for ethylene inserting in the polymeryl chain of theoriginal species (2), the product of inserting into the aryl orhydrocarbyl group (3), and the product of inserting into the polymerylchain (4). The stationary points defined as transition states wereconfirmed by one and only one imaginary frequency (corresponding to thereaction coordinate) as determined from mass-weighting of theeigenvalues from the diagonalization of the second derivative or Hessianmatrix. The two products, 3 and 4, have no imaginary frequencies uponthis analysis.

In examples involving ethylene/octene, more than one potential‘inserted’ catalyst could be formed. Diagram 2 depicts the four possibleoctene inserted catalysts from one face. These four unique catalystseach could create polymer with different properties such as molecularweight and comonomer incorporation.

Insertions can occur on the top and bottom faces of the catalyst andthese can be unique depending on the overall symmetry of the initialcatalyst (Diagram 3). For the specific catalyst below, insertions intothe top and bottom faces lead to unique isomers. Thus forethylene/octene polymerizations, up to ten unique ‘inserted’ catalystsare possible. The aforementioned calculations indicate that not all arefavorable, but certainly more than one is possible. As described above,the Applicants have determined that different conditions can be used tofavor one or some over others.

Based on catalyst activity such as the one above, barriers important forthe polymerization may be estimated. If insertion into the aryl orhydrocarbyl is less than 10 kcal/mol higher than insertion into thealkyl, this reaction should occur during the polymerization cycle. FromDiagrams 1 and 4, this implies that TS 1 lies no higher than 10 kcal/molabove TS 2. It is preferable that this difference is less than 5kcal/mol and even more preferable that insertion into the aryl orhydrocarbyl is less than insertion into the alkyl. Insertion into thealkyl is not a reversible process, but to avoid reversibility ofinsertion into the aryl or hydrocarbyl, the product of insertion intothe aryl or hydrocarbyl cannot lie more than 5 kcal/mol above insertioninto the alkyl. From Diagrams 1 and 4, this implies that Product 3 liesno higher than 5 kcal/mol above Product 4. However, it is preferablethat this difference is less and even more preferable that the productof aryl or hydrocarbyl insertion is lower than the product of alkylinsertion. Diagram 4 depicts a potential energy surface of the twoprocesses.

One skilled in the art may apply the above principles in selectingreaction conditions and catalyst to achieve a desired controlledmolecular weight.

What is claimed is:
 1. An ethylene/α-olefin interpolymer which has (i) aDSC curve characterized by an area under the DSC curve from the meltingpeak temperature to the end of melting is at least about 17% of thetotal area under the DSC melting curve from −20° C. to the end ofmelting; (ii) a density from about 0.875 g/cc to about 0.915 g/cc; and(iii) a I₁₀/I₂ from 5.5 to 6.5.
 2. The ethylene/α-olefin interpolymer ofclaim 1 having no long chain branching.
 3. The ethylene/α-olefininterpolymer of claim 1 which has a DSC curve characterized by an areaunder the DSC curve from the melting peak temperature to the end ofmelting is at least about 19% of the total area under the DSC meltingcurve from −20° C. to the end of melting.
 4. The ethylene/α-olefininterpolymer of claim 1 which has a DSC curve characterized by an areaunder the DSC curve from the melting peak temperature to the end ofmelting is from at least about 19% to about 35% of the total area underthe DSC melting curve from −20° C. to the end of melting.
 5. Theethylene/α-olefin interpolymer of claim 1 which has a DSC curvecharacterized by an area under the DSC curve from the melting peaktemperature to the end of melting is at least about 21% of the totalarea under the DSC melting curve from −20° C. to the end of melting. 6.The ethylene/α-olefin interpolymer of claim 1 which has a density fromabout 0.895 g/cc to about 0.910 g/cc.
 7. The ethylene/α-olefininterpolymer of claim 1 wherein the I₁₀/I₂ is from about 5.6 to about6.3.
 8. The ethylene/α-olefin interpolymer of claim 1 wherein theinterpolymer has a molecular weight distribution in the range from about2.0 to about 3.8.
 9. The ethylene/α-olefin interpolymer of claim 1wherein the interpolymer has a molecular weight distribution in therange from about 2.2 to about 2.8.
 10. The ethylene/α-olefininterpolymer of claim 1 which has a B value of greater than about 0.98.11. The ethylene/α-olefin interpolymer of claim 1 having a density from0.895 g/cc to 0.915 g/cc.
 12. The ethylene/α-olefin interpolymer ofclaim 1 wherein the ethylene/α-olefin interpolymer is an ethylene/octenecopolymer.
 13. A film comprising: an ethylene/α-olefin interpolymerwhich has (i) a DSC curve characterized by an area under the DSC curvefrom the melting peak temperature to the end of melting is at leastabout 17% of the total area under the DSC melting curve from −20° C. tothe end of melting; (ii) a density from about 0.875 g/cc to about 0.915g/cc; and (iii) a I₁₀/I₂ from 5.5 to 6.5.
 14. The film of claim 13wherein the ethylene/α-olefin interpolymer has no long chain branching.15. The film of claim 13 wherein the ethylene/α-olefin interpolymer hasa density from about 0.895 g/cc to about 0.915 g/cc.
 16. The film ofclaim 13 wherein the ethylene/α-olefin interpolymer has a I₁₀/I₂ fromabout 5.6 to about 6.3.
 17. A multilayer film comprising: a) a baselayer comprising a first polymer; b) a tie layer comprising a secondpolymer; and c) a sealant layer comprising an ethylene/α-olefininterpolymer, wherein the tie layer is between the base layer and thesealant layer and wherein the ethylene/α-olefin interpolymer of thesealant layer has (i) DSC curve characterized by an area under the DSCcurve from the melting peak temperature to the end of melting is atleast about 17% of the total area under the DSC melting curve from −20°C. to the end of melting; (ii) a density from about 0.875 g/cc to about0.915 g/cc; and (iii) a I₁₀/I₂ from 5.5 to 6.5.
 18. The multilayer filmof claim 17 wherein the ethylene/α-olefin interpolymer has no long chainbranching.
 19. The ethylene/α-olefin interpolymer of claim 17 which hasa density from about 0.895 g/cc to about 0.915 g/cc.
 20. Theethylene/α-olefin interpolymer of claim 17 wherein the I₁₀/I₂ is fromabout 5.6 to about 6.3.